Concentric Induction Coil Heating for Bearing Temperature Control

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Solution Overview

Problem

Existing induction heating devices face challenges in rapidly heating metal articles, such as bearings, without exceeding safe temperature limits, which can damage components like lubricants and seals due to rapid heating rates leading to temperature overshooting.

Innovation Solution

An induction heating device with a support plate and concentrically arranged induction coils, connected to a generator, and at least one temperature probe to monitor and control heating, employing a method that adjusts heating strategies based on temperature measurements to maintain maximum heating speed while limiting temperature differences between inner and outer rings, and incorporating steps to ensure the target temperature is reached without overshooting.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the heating rate is increased to heat the metal article faster, then the productivity is improved, but the temperature control precision deteriorates leading to temperature overshooting

Engineering Contradiction:

Improveheating speedVSAvoidtemperature control precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The heating system is divided into multiple independent induction coils (first coil, second coil, third coil) arranged concentrically at different positions. Each coil can be controlled independently to heat different regions of the bearing, allowing selective heating of the inner ring versus the outer ring to manage temperature distribution and prevent overheating while maintaining high heating rates

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system dynamically adjusts the power distribution to each induction coil based on real-time temperature feedback from multiple thermocouples. The controller continuously modifies the heating parameters during the process, switching between different coil configurations and power levels to optimize both heating speed and temperature control precision throughout the heating cycle

Inventive Principle:

Principle #15Dynamics

2Productivity

If the heating power is increased to reduce heating time, then the productivity is improved, but the reliability deteriorates due to damage risk to lubricant and seals

Engineering Contradiction:

Improveheating timeVSAvoidcomponent integrity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

Different regions of the bearing are heated with different power levels through the concentric coil arrangement. The inner ring can be heated more intensively than the outer ring or lubricated areas, allowing rapid heating of critical metal components while protecting heat-sensitive elements like lubricant and seals from excessive temperatures that would compromise reliability

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If multiple temperature probes are used to monitor different regions, then the temperature control precision is improved, but the device complexity increases

Engineering Contradiction:

Improvetemperature monitoring accuracyVSAvoidnumber of temperature probes

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Multiple thermocouples (temperature probes) are strategically positioned at key locations including the inner ring and outer ring of the bearing. The controller integrates feedback from all these probes to compute a comprehensive temperature profile, merging the information from multiple sensors to achieve precise overall temperature control without requiring each probe to independently control a separate heating zone

Inventive Principle:

Principle #5Merging (Combining)

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

Enables rapid heating of metal articles without risking temperature overshoot, maintaining safe temperature differences between inner and outer rings, thus preventing damage to bearings and ensuring precise temperature control.

Implementation Method 1

induction coils for heating a metal article, such as a rolling element bearing, a ring or a gear, by inducing eddy currents in the metal article

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

heating a metal article, such as a rolling element bearing, a ring or a gear, by inducing eddy currents in the metal article

Methodology Applied

Scientific EffectEddy currents: Eddy Currents

Implementation Method 3

Induction heaters typically include one or more induction coils for heating a metal article

Methodology Applied

Scientific EffectInduction heating: Induction Heating

Data Source

PatentUS11711872B2Induction heating device

Publication Date: 2023.07.25 AB SKF SKF PATENT DEPARTMENT

AI summary

An induction heating device for heating a metal article includes a support plate with an upper surface for receiving the metal article, and a plurality of induction coils, which are arranged concentrically around an axis and are provided at an underside of the support plate. Each induction coil is connected to and selectively powered by a generator, and at least one temperature probe is disposeable on the metal article during heating in order to monitor and control the heating of the article.