Induction Heating Coil Segmentation for Uniform Tube Heating
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Solution Overview
Problem
Existing induction heating coils struggle to uniformly heat metal tubes in the circumferential direction while maintaining a narrow heated region in the axial direction, leading to non-uniform temperature distribution and reduced accuracy in manufacturing processes.
Innovation Solution
The design of an induction heating coil with a first and second 1-turn coil body, positioned in a specific configuration to ensure uniform heating, where the effective coil length is closely aligned with the inner coil length, minimizing non-effective coil length to less than 5% of the inner coil length, and the connecting portions are strategically placed to maintain consistent current flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional induction heating coils are used to heat metal tubes, then heating can be performed, but uniform heating in the circumferential direction cannot be achieved while maintaining a narrow heated region in the axial direction
Solution Approach 1:
The induction heating coil is divided into multiple 1-turn coil bodies arranged in the axial direction, with each coil body contributing to uniform heating in the circumferential direction while the segmented structure enables precise control of the heated region width in the axial direction
Solution Approach 2:
The coil connecting portions are strategically positioned to create local variations in current flow, ensuring that the effective coil length is minimized (less than 5% of inner coil length) while maintaining uniform heating characteristics across the heated region
2Manufacturing precision
If the coil connecting portions are positioned to minimize non-effective coil length, then heating accuracy improves, but current flow uniformity may be affected
Solution Approach 1:
The coil connecting portions are positioned asymmetrically at specific locations (e.g., at 45° or 135° from the top view) to minimize the non-effective coil length in critical heating zones while maintaining overall current flow stability through strategic placement
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 stable, uniform heating of metal tubes in the circumferential direction and a narrow axial region, enhancing the accuracy and reliability of the manufacturing process by reducing temperature differences and improving dimensional consistency.
Implementation Method 1
an induction heating coil which performs induction heating of an elongated metal material
Implementation Method 2
in order to uniformly heat the member being heated in the circumferential direction, induction heating is carried out
Data Source
AI summary
An induction heating coil for stably heating a steel tube which is being fed in its axial direction without rotating, the heating being uniform in the circumferential direction and in a narrow range in the axial direction has at least two 1-turn coils in the form of a first turn coil body and a second turn coil body. The inner peripheral length Ln (the non-effective coil length) where the effective number of coil turns is less than the total number of coil turns when the coil is projected in the axial direction and the inner peripheral length L0 of the projected coil bodies (the inner coil length) satisfy Ln/L0<0.05. First and second coil bodies have insulating portions on their connecting portions, and the insulating portions are present in locations separated by a central angle of 5-45° measured from the center of the coil bodies.