Induction Coil Assembly Using Pulse Detection for Tool Holder Heating
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Solution Overview
Problem
Existing induction coil assemblies require significant manual intervention and adjustment for efficient operation, leading to extended cycle times and potential errors, especially when handling different tool holders, which can result in inefficient heating and risk of tool holder overheating or destruction.
Innovation Solution
An induction coil assembly with a method for controlling the inductive heating process that uses test and control pulses to determine the sleeve section's characteristics, allowing for automated operation by applying defined currents to recognize the sleeve section, set heating parameters, and monitor the heating process, thereby reducing manual intervention and ensuring safe and efficient heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual adjustment is performed for each tool holder, then heating efficiency is improved, but cycle time increases and operational complexity increases
Solution Approach 1:
The system automatically detects tool holder parameters and adjusts heating parameters without manual intervention. The control unit reads tool holder data from memory, determines appropriate heating parameters, and executes the heating process autonomously, eliminating the need for manual adjustment while maintaining heating efficiency.
Solution Approach 2:
The patent replaces manual mechanical adjustment with an automated electronic control system. The control unit uses electronic memory to store tool holder parameters and automatically retrieves and processes this information, substituting the manual mechanical adjustment process with an electronic automation system that reduces cycle time while maintaining or improving heating efficiency.
2Ease of operation
If heating parameters are not properly adjusted, then operational simplicity is improved, but tool holder damage risk increases
Solution Approach 1:
The control unit automatically determines appropriate heating parameters based on detected tool holder characteristics, eliminating the need for manual parameter adjustment. This maintains operational simplicity while preventing tool holder damage through automated parameter optimization that ensures heating parameters are always appropriate for the specific tool holder being processed.
Solution Approach 2:
The system performs preliminary detection and parameter determination before the heating process begins. The control unit reads tool holder parameters from memory, determines appropriate heating parameters in advance, and prepares the heating process with correct parameters before actual heating starts, preventing damage while maintaining operational simplicity.
3Loss of time
If automated detection is implemented, then cycle time is reduced and operational reliability is improved, but device complexity increases
Solution Approach 1:
The control unit serves multiple functions: it detects tool holder parameters, retrieves stored parameter data from memory, determines optimal heating parameters, and controls the heating process. By consolidating these functions into a single multi-functional control unit, the system reduces cycle time through automation while minimizing the increase in device complexity through functional integration rather than adding separate components for each function.
Solution Approach 2:
The patent replaces manual mechanical adjustment processes with electronic detection and control systems. The automated detection system uses electronic sensors and memory to identify tool holder parameters and retrieve stored data, replacing complex manual adjustment mechanisms with simpler electronic systems that reduce cycle time while the integration of these electronic systems into the existing control architecture minimizes overall device 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 solution enables automated and efficient inductive shrinking of tools with reduced cycle times, improved operational reliability, and protection against overheating, maintaining high standards of operational safety and efficiency.
Implementation Method 1
induction coil assembly with an induction coil (1), into which a sleeve section (HP) of a tool holder (4) can be inserted
Implementation Method 2
thermally expand tool holders using alternating magnetic fields generated by induction coils and the eddy currents thus induced in the tool holders incorporated in the induction coils
Implementation Method 3
After the tool holder has cooled down, the tool is then held firmly and symmetrically by the tool holder. This process is also referred to as inductive shrinking of tools into tool holders
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
The invention relates to an induction coil assembly comprising an induction coil into which a sleeve portion of a tool holder can be inserted, and a method for controlling an inductive heating process for an induction coil assembly with a sleeve portion of a tool holder inserted into an induction coil of the induction coil assembly. To increase the degree of automation in an induction coil assembly, it is provided that: - a defined, predetermined (test) current (test pulse) is applied to the induction coil before the start of an inductive heating process for the sleeve portion inserted into the induction coil; - a time/current curve is determined for this (test) current (test pulse) for the sleeve portion inserted into the induction coil; and - the inserted sleeve portion is identified based on the time/current curve of the (test) current.- Heating parameters are defined for the sleeve section inserted into the induction coil based on the detection, and the inductive heating process is started based on the heating parameters defined for the detected sleeve section; - the inductive heating process is interrupted at least once, during which a defined (control) current (control pulse) is applied to the induction coil at the sleeve section inserted into the induction coil, and a further time/current curve is determined for this (control) current (control pulse) for the sleeve section inserted into the induction coil; - based on the further time/current curve of the (control) current, a decision is made as to whether the heating process is continued or finally terminated.