Induction Heating Circuit Layout for Metal Plate Edge Heating
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Solution Overview
Problem
Existing induction heating methods for metal plates, such as C-shaped inductors, inefficiently heat a wide range beyond the end portions, leading to high power consumption and potential device damage, and flame heating methods have low heating efficiency and require ancillary equipment.
Innovation Solution
An induction heating device with conductor members separated by a specific distance forms a primary closed circuit, generating induced currents that heat only the end portions of the metal plate, using an AC power supply to create a secondary closed circuit for efficient heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a C-shaped inductor is used to heat end portions of metal plate, then end cracking is prevented, but a wide range beyond end portions is induction-heated causing high power consumption
Solution Approach 1:
The inductor is divided into multiple independent conductor members (first conductor member, second conductor member, third conductor member) that can be independently controlled. Each conductor member heats a specific region, allowing selective heating of only the end portions without heating the wide range beyond them, thus reducing power consumption while preventing end cracking.
Solution Approach 2:
Different regions of the metal plate are subjected to different heating conditions. The conductor members are positioned and controlled to apply heating locally only to the end portions that require temperature increase for preventing end cracking, rather than heating the entire plate or wide ranges beyond the ends.
2Manufacturing precision
If inductor gap is narrowed to heat only end portions, then heating precision is improved, but device may be damaged due to contact with poor shape material
Solution Approach 1:
The heating system is segmented into multiple conductor members with larger gaps between them. This segmentation allows each conductor member to be positioned at a safe distance from the metal plate, preventing contact damage while maintaining precise control over the heating range through independent activation of specific conductor members.
Solution Approach 2:
The connecting members serve as intermediaries that connect the conductor members while allowing for movement and positioning adjustments. This intermediary structure enables the conductor members to maintain optimal heating precision without requiring narrow gaps that would risk contact with the metal plate.
3Power
If flame heating is used for end portions, then heating capability is provided, but heating efficiency is low and ancillary equipment is required
Solution Approach 1:
The mechanical flame heating system is replaced with an electromagnetic induction heating system using conductor members. This substitution eliminates the need for fuel combustion and ancillary equipment such as flame detection mechanisms and movement control devices, while providing high heating efficiency and capability through direct electromagnetic energy transfer to the metal plate.
4Reliability
If C-shaped inductor is used to sandwich end portions, then end cracking is prevented, but ancillary equipment such as detection mechanism and movement mechanism is required
Solution Approach 1:
The inductor is segmented into multiple independent conductor members that can be independently controlled. This segmentation eliminates the need for complex movement mechanisms and detection systems required by C-shaped inductors, as each conductor member can be independently activated to heat the end portions and prevent cracking without requiring precise positioning mechanisms.
Solution Approach 2:
The conductor members are positioned and configured to automatically heat the end portions of the metal plate as it passes through the heating device. The system is designed to self-regulate the heating process without requiring ancillary detection mechanisms or movement control devices, simplifying the overall equipment complexity.
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
The method effectively heats only the end portions of the metal plate, preventing end cracking and improving rolling dimensional accuracy while reducing power consumption and eliminating the need for ancillary equipment.
Implementation Method 1
an AC power supply connected to the primary closed circuit
Implementation Method 2
generating induced currents that heat only the end portions of the metal plate
Implementation Method 3
heat only the end portions of the metal plate
Data Source
AI summary
Provided is an induction heating device for a metal plate including: a first conductor member that faces at least one of a front surface or a back surface of the metal plate and that is disposed across the metal plate in a width direction; a second conductor member that is separated from the first conductor member by a first distance in a plate passing direction of the metal plate, that faces at least one of the front surface or the back surface of the metal plate, and that is disposed across the metal plate in the width direction; connecting members that connect the first conductor member and the second conductor member to each other at positions separated from width-directional end portions of the metal plate to form a primary closed circuit; and an AC power supply connected to the primary closed circuit, in which the first distance is larger than a sum of dimensions of the first conductor member and the second conductor member in the plate passing direction of the metal plate.