3D Printed Induction Coil Assembly with Integrated Fluid Passages
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Solution Overview
Problem
Manual manufacturing techniques for copper induction coil assemblies are time-consuming, lack dimensional accuracy, and are prone to distortion, which reduces the efficiency of heat treatment and makes it difficult to produce components with complex dimensions.
Innovation Solution
The use of a 3D printing method to manufacture induction coil assemblies, specifically an annular member and legs with integrated fluid passages and electrical connections, allowing for precise construction and improved dimensional accuracy, and the integration of a cooling system for efficient heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual manufacturing techniques are used to manufacture copper induction coil assemblies, then flexibility in manufacturing process is maintained, but manufacturing time is excessive and dimensional accuracy is poor
Solution Approach 1:
The patent combines multiple manufacturing operations into a single automated 3D printing process. The induction coil components are printed directly in their final configuration, eliminating the need for separate steps such as cutting, bending, welding, and assembly that are required in manual manufacturing. This integration of operations achieves both high dimensional accuracy and reduced manufacturing time.
Solution Approach 2:
The patent replaces manual mechanical manufacturing techniques with automated 3D printing technology. Instead of using traditional tools for cutting, shaping, and assembling copper components, the invention uses additive manufacturing to directly create the induction coil components with precise dimensional control, thereby eliminating time-consuming manual operations while maintaining manufacturing flexibility.
2Reliability
If manual manufacturing techniques are used, then simple manufacturing processes are maintained, but the induction coil assembly is susceptible to distortion during heat treatment
Solution Approach 1:
The patent performs preliminary shaping and positioning of the induction coil components during the 3D printing process itself. The components are manufactured with their final precise geometry and proper spatial orientation before heat treatment, ensuring they maintain their intended configuration during subsequent thermal processing. This preliminary formation of the final structure prevents distortion that would otherwise occur with manually formed components.
3Adaptability or versatility
If manual manufacturing techniques are used, then manufacturing simplicity is maintained, but components with complex dimensional characteristics cannot be manufactured
Solution Approach 1:
The patent utilizes the ability of 3D printing to easily change geometric parameters and configurations through software control. Complex dimensional characteristics such as variable cross-sections, non-standard geometries, and intricate internal structures can be achieved by modifying digital design parameters rather than requiring complex manual fabrication processes. This allows rapid adaptation to different design requirements without increasing physical manufacturing 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 3D printing method enables the production of induction coil assemblies with precise dimensional characteristics, enhancing the efficiency of heat treatment operations and allowing for the manufacture of components with complex dimensions, thereby improving the overall performance and accuracy of heat treatment processes.
Implementation Method 1
induction coils are supplied with an electric power to generate electromagnetic field. Such electromagnetic field generates induced electric current within an electrically conducting component disposed in proximity of the induction coil. The induced electric current generates heat within the electrically conducting component.
Implementation Method 2
An internal surface of the annular member defines a first fluid passage through the annular member. An internal surface of the first leg defines a second fluid passage through the first leg, and a wall of the first leg defines a first fluid port in fluid communication with the second fluid passage.
Data Source
AI summary
An induction coil assembly includes an annular member extending from a first end to a second end, and extending about a longitudinal axis; a first leg extending from the first end of the annular member, and including a first electrical connection portion and a first axial portion; and a second leg extending from the second end of the annular member, and including a second electrical connection portion and a second axial portion. An internal surface of the annular member defines a first fluid passage through the annular member. An internal surface of the first leg defines a second fluid passage through the first leg. An internal surface of the second leg defines a third fluid passage through the second leg. The second fluid passage is in fluid communication with the third fluid passage via the first fluid passage.