Impulse Current Generator Energy Recuperation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing surge current generators for electromagnetic forming of workpieces suffer from inefficient energy recuperation, leading to energy loss and increased thermal and mechanical stress on the tool coil, as the second current half-wave is not effectively controlled, causing the capacitor to discharge prematurely and reducing the usable energy for workpiece formation.
Innovation Solution
A triggered recuperation arrangement with a reverse-blocking inductance and a self-extinguishing switch is introduced, allowing the second current half-wave to flow only after a predetermined time interval following the zero crossing of the first current half-wave, ensuring the capacitor is recharged to its original polarity and preventing unnecessary energy loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a recuperation arrangement is introduced to enable second current half-wave flow, then energy recuperation is improved, but device complexity increases due to additional components
Solution Approach 1:
A diode is introduced as an intermediary component in the recuperation arrangement to control current flow direction. The diode allows current to flow during the second half-wave for energy recuperation while blocking reverse current, enabling energy recovery without requiring complex active switching components.
Solution Approach 2:
The recuperation arrangement utilizes the inherent oscillating circuit behavior of the capacitor and tool coil to automatically generate and control the second current half-wave. The system self-regulates the energy recovery process through passive components (capacitor, inductor, diode) without requiring external control systems or complex active management.
2Loss of energy
If the second current half-wave is allowed to flow through the tool coil, then energy is recovered, but thermal and mechanical stress on the tool coil increases
Solution Approach 1:
The harmful second current half-wave is extracted from the main tool coil circuit by introducing a parallel recuperation arrangement. The diode directs the second half-wave current through the recuperation path instead of through the tool coil, separating the energy recovery function from the forming function and eliminating thermal and mechanical stress on the tool coil during recovery.
Solution Approach 2:
The current path is segmented into two separate pathways: one for the first half-wave through the tool coil for workpiece forming, and another for the second half-wave through the recuperation arrangement for energy recovery. This segmentation allows each component to perform its function without suffering harmful effects from the other current direction.
3Loss of energy
If the capacitor discharges during the second current half-wave, then energy is recovered, but the polarity reversal causes premature discharge and reduces usable energy
Solution Approach 1:
The capacitor's natural polarity reversal during oscillation, which was previously causing premature discharge and energy loss, is converted into a beneficial feature. The diode arrangement captures the reversed polarity state and channels it through the recuperation path, transforming what was a harmful effect into the mechanism for energy recovery during the second half-wave.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables improved energy recuperation, reducing thermal and mechanical stress on the tool coil and ensuring that the energy stored in the capacitor is effectively reused for subsequent workpiece forming, enhancing the overall efficiency of the surge current generator.
Implementation Method 1
The chargeable capacitor, which can be charged to a predetermined original polarity, for example by means of a charging device or a charging device of the surge current generator, essentially forms an oscillating circuit with the inductance of the tool coil
Implementation Method 2
applied a high, short-term, pulse-like current to a tool coil that causes the workpiece forming, in order to thereby generate an electromagnetic field in the tool coil, which in an electrically conductive Workpiece generates eddy currents
Implementation Method 3
parallel to the at least one capacitor and the tool coil a recuperation arrangement with an inductance, which is further connected by a diode, which is in series with the inductance, for a second current half-wave
Data Source
Figure 1~2
AI summary
The invention relates to an impulse current generator of a device for the electromagnetic forming of workpieces, comprising at least one capacitor (1) that can be charged with a predetermined initial polarity. In a first current half-wave, the capacitor can be discharged and charged to the reverse polarity via a triggerable switching arrangement (2a, 2b) that allows the first current half-wave to pass through, is reverse-blocking, and self-extinguishing at the current zero crossing. This switching arrangement is conducted by a tool coil (3) that effects the workpiece forming during the current flow. A recuperation arrangement (4a, 4b) that allows a second current half-wave to pass through, is reverse-blocking, and has an inductor (4a). This recuperation arrangement allows the at least one capacitor (1) to be discharged and recharged to the original polarity in the second current half-wave.4b) is triggered at a time interval from the zero crossing of the first current half-wave. The invention further relates to a method for its operation.