Induction Heating Coil Mist Cooling for Scale Removal
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Solution Overview
Problem
Existing induction heating apparatuses face issues with temperature unevenness and coil damage due to scale deposition, requiring complex coil designs or additional cooling systems to manage heating distribution and prevent overheating in workpieces with varying shapes.
Innovation Solution
A heating apparatus that uses a coil with adjustable heating sections and a mist-based cooling fluid system to continuously heat elongated workpieces, where the cooling fluid is sprayed as fine particles to both the coil and workpiece, effectively removing scales and burrs while controlling temperature distribution by adjusting the spray direction and amount.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cooling fluid is sprayed to the coil during heating to remove scales, then coil damage from short circuit is prevented, but temperature unevenness occurs on the workpiece due to cooling fluid scattering
Solution Approach 1:
A partition wall is introduced as an intermediary structure between the cooling fluid spray source and the workpiece. This partition wall intercepts and redirects the cooling fluid flow, preventing direct contact between the cooling fluid and the workpiece surface, thereby eliminating temperature unevenness while maintaining scale removal functionality
Solution Approach 2:
The heating apparatus is divided into distinct functional zones: a heating zone with the coil and workpiece, and a separate cooling zone with the spray source. The partition wall physically segments these zones, allowing independent optimization of heating and cooling functions without mutual interference
2Temperature
If the heating process is completed and workpiece is taken out before spraying cooling fluid to the coil, then temperature unevenness is avoided, but scales are deposited on the coil causing short circuit
Solution Approach 1:
The cooling fluid spray system is activated during the heating process itself, performing the scale removal action in advance before scales can accumulate to dangerous levels. This preliminary action prevents the need to stop heating for scale removal, maintaining both temperature uniformity and coil reliability
3Productivity
If the coil is relatively moved with respect to the continuously fed workpiece for efficient heating, then productivity is improved, but the heating time is extended allowing scale deposition on the coil
Solution Approach 1:
The cooling fluid spray operates continuously throughout the heating process, maintaining constant scale removal action. This continuous protective action ensures that even during extended relative movement for efficient continuous heating, scales cannot accumulate on the coil to cause short circuits
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 configuration allows for uniform heating, prevents coil damage, and reduces manufacturing costs by simplifying coil design, while maintaining desired heat treatment quality across different workpiece sizes and shapes without the need for magnetic shields.
Implementation Method 1
a workpiece is inductively heated by a magnetic field formed by a coil to which AC power is supplied
Implementation Method 2
cooling fluid such as water is also sprayed to a coil so that scales attached to the coil are removed
Data Source
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AI summary
A heating apparatus and a heating method are provided. The heating apparatus includes a coil configured to receive AC power to form a magnetic field that inductively heats a workpiece, a spray unit configured to spray cooling fluid including a liquid to a heating target portion of the workpiece placed in the magnetic field in a form of a mist at least during the period in which the AC power is supplied to the coil.