Induction Coil Condensate Prevention via Joule Heating
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Solution Overview
Problem
The induction heat generation roller device faces issues with insulation performance degradation due to condensate formation on the induction coil, which is exacerbated by the use of coolant mist cooling, leading to potential heat-resistant resin or inorganic cement solutions that are not entirely effective in preventing water penetration.
Innovation Solution
Incorporating a DC voltage application part to generate Joule heat in the induction coil, which prevents condensate formation and evaporates any adhering water, while the coolant mist is introduced after AC voltage termination to effectively cool the roller main body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If coolant mist is supplied continuously to cool the roller main body, then the roller temperature is maintained within target range, but condensate forms on the induction coil reducing insulation performance
Solution Approach 1:
A heating element is provided on the induction coil to preheat or maintain the coil temperature above the dew point before coolant mist is supplied. This preliminary heating action prevents condensate formation on the coil surface when coolant mist contacts the roller main body, thereby maintaining insulation performance while enabling effective cooling.
Solution Approach 2:
The heating element acts as an intermediary between the coolant mist and the induction coil. By introducing this intermediate heating component, the system prevents direct harmful interaction (condensation) between the cool mist and the coil, protecting the insulation while allowing the cooling function to operate.
2Use of energy by moving object
If AC voltage is minimized to reduce heating, then energy consumption is reduced, but the induction coil temperature drops causing coolant condensation
Solution Approach 1:
The system changes the temperature parameter of the induction coil by introducing a heating element that can independently control coil temperature. This allows the coil to be maintained at a temperature above the dew point even when AC voltage to the roller is minimized, preventing condensation while reducing overall energy consumption for cooling.
3Reliability
If resin barrier layer is applied to protect induction coil, then insulation is improved, but defective parts and cementing make protection incomplete
Solution Approach 1:
The solution extracts the protection function from the resin barrier layer and relocates it to the heating element. Instead of relying on a physical barrier that is prone to defects and cementing issues, the system uses active thermal management to prevent condensation at its source, providing more reliable protection without manufacturing precision concerns.
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
Prevents insulation performance degradation by ensuring minimal condensate formation on the induction coil, allowing for efficient temperature control and effective cooling of the roller main body.
Implementation Method 1
a DC voltage application part configured to apply a DC voltage to the induction coil... the induction coil to generate Joule heat, thereby enabling the heating of the induction coil itself
Implementation Method 2
an induction heat generator provided within the roller main body and having an induction coil for heating the roller main body inductively
Implementation Method 3
a latent heat of vaporization which is generated when the coolant mist contacts with an inner surface of the roller and vaporizes
Implementation Method 4
a sensible heat that is generated due to a temperature increase of the coolant mist between the roller main body and the induction heat generator
Data Source
AI summary
The present disclosure, for the prevention of a possible degradation of an induction coil in insulating performance by preventing condensate formation on an induction coil, provides a device that is configured to include a roller main body, an induction heat generator provided in the roller main body and having the induction coil for heating the roller main body inductively, a cooling mechanism configured to introduce a coolant mist into a clearance portion between the roller main body and the induction heat generator for cooling the roller main body, an AC voltage application part configured to apply AC voltage to the induction coil, and a DC voltage application part configured to apply DC voltage to the induction coil.