Induction Coil Ring Attachment via High-Energy Forming and Diffusion Welding
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Solution Overview
Problem
Existing methods for attaching conductive turns in induction coils for electromagnetic forming face issues with electrical losses, mechanical complexity, and high costs due to gaps between the turn and frame, leading to inefficiencies and potential coil destruction from radial forces.
Innovation Solution
A method involving high-energy forming and diffusion welding to securely attach a metal ring with high electrical conductivity in a frame, ensuring complete electrical continuity and mechanical stability by eliminating gaps and using materials like copper and steel, with induction heating for efficient bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conductive turn made of copper or another material having good electrical conductivity is combined with a framework made of a rigid material such as steel, then the coil structure becomes mechanically stable, but electrical losses occur in the region of the gap remaining between the turn and the frame
Solution Approach 1:
The invention changes the physical state and surface properties of the metal ring through high-energy forming and diffusion welding processes. The high-energy forming deforms the ring at speeds greater than 15 m/s to achieve intimate contact with the frame, while diffusion welding creates a metallurgical bond that eliminates gaps, thereby reducing electrical losses while maintaining mechanical stability.
2Strength
If a conductive turn is fixed in a steel frame by means of clamping by a plurality of screws, then the assembly becomes mechanically stable, but the mechanical complexity increases and the device becomes costly
Solution Approach 1:
The invention extracts and eliminates the complex clamping screw mechanism from the assembly. Instead of using multiple screws to clamp the conductive turn to the frame, the invention uses high-energy forming and diffusion welding to create a direct, gap-free connection between the metal ring and the frame, thereby simplifying the mechanical structure while maintaining stability.
Solution Approach 2:
The invention merges the attachment function with the structural connection by using diffusion welding to create a metallurgical bond between the metal ring and the frame. This eliminates the need for separate clamping mechanisms and integrates the electrical and mechanical connections into a single unified structure.
3Ease of manufacture
If the presence of a gap remains between the frame and the turn, then the assembly is easier to manufacture, but electric arcs form between the frame and the turn which seriously negatively affect the properties for transferring current
Solution Approach 1:
The invention performs preliminary high-energy forming and diffusion welding actions during the manufacturing process to eliminate gaps before the coil is put into service. The high-energy forming process deforms the metal ring at high speeds to achieve intimate contact with the frame, and diffusion welding creates a permanent metallurgical bond, preventing gap formation and electric arcs in subsequent operation.
4Manufacturing precision
If high-energy forming is used to press the ring against the bore at a deformation speed greater than 15 m/s, then impurities are driven out from the interface, but the process requires high energy input
Solution Approach 1:
The high-energy forming process uses periodic or pulsed energy input to achieve the required deformation speeds greater than 15 m/s. This allows the system to accumulate and release energy in controlled bursts, achieving the high-speed deformation needed to drive out impurities from the interface while managing the overall energy input through timing and duration control.
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 method achieves a durable, efficient, and cost-effective induction coil with improved performance and extended operational life by ensuring close contact and diffusion welding between dissimilar materials, preventing electrical arcs and mechanical stress, thus enhancing both electrical and mechanical properties.
Implementation Method 1
the ring is set in the bore by means of high-energy forming suitable for pressing an outer surface of the ring against the bore at a deformation speed of greater than 15 m/s, which is capable of driving out any impurities from an interface between the ring and the frame
Implementation Method 2
the interface between the ring and the frame is heated to a temperature and for a length of time that are determined in accordance with the respective materials of the ring and the frame so as to obtain diffusion welding between the outer surface of the ring and the bore
Implementation Method 3
The techniques of electromagnetic forming or magnetic pulse welding, which are known for example from BE582117, make it possible to shape metals, or even to weld them by means of deformations applied by a magneto-mechanical force resulting from the interaction between the Laplace forces and the induced currents generated in a metal part as a result of a sudden change in a magnetic field
Data Source
AI summary
A method for attaching a metal ring (4) in a bore (3) of a frame (2) made of a different metal, wherein: the ring (4) is set in the bore (3) by way of high-energy forming suitable for urging an outer surface of the ring against the bore (3) with a speed capable of driving out any impurity from an interface between the ring and the frame; the interface between the ring (4) and the frame (2) is heated to a temperature and for a length of time that are determined in accordance with the respective materials of the ring and the frame such as to obtain diffusion welding between the outer surface of the ring and the bore. A single-turn coil for magnetic forming carried out by the method is also described.