Induction Coil Layout for Uniform Heating of Ring Workpieces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing heat treatment methods using helical coils for inductively heating ring-shaped workpieces, such as raceway rings for rolling bearings, face challenges in achieving uniform temperature distribution across the workpiece's circumference and require significant effort to adjust the coil pitch for varying workpiece dimensions.
Innovation Solution
A heat treatment apparatus with a frame-supported coil member configuration allows for easy adjustment and setting of the coil pitch in the axial direction, forming distinct temperature increasing and soaking zones to ensure uniform heating without altering the coil shape or pitch in the circumferential direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a helical coil with adjusted coil pitch is used to heat workpieces sequentially, then energy efficiency is improved and apparatus size is reduced, but temperature uniformity in the circumferential direction deteriorates
Solution Approach 1:
The patent divides the single helical coil into multiple separate coil members (first coil member and second coil member) that can be independently adjusted. This segmentation allows each coil member to be positioned to create a temperature increasing zone and a soaking zone, thereby achieving both energy efficiency and temperature uniformity through modular configuration.
Solution Approach 2:
The patent introduces adjustable support structures that enable dynamic repositioning of the coil members along the axial direction. This dynamic adjustment capability allows the coil pitch to be optimized for different workpiece dimensions and heating requirements, maintaining temperature uniformity while preserving the energy efficiency benefits of induction heating.
2Adaptability or versatility
If the coil pitch is adjusted to accommodate varying workpiece dimensions, then adaptability is improved, but device complexity and adjustment effort increase
Solution Approach 1:
The patent employs adjustable support structures with movable components that allow simple repositioning of coil members along the axial direction. This dynamic adjustment mechanism provides adaptability to different workpiece dimensions while maintaining relatively simple device structure and easy operation.
Solution Approach 2:
By dividing the coil system into separate, independently adjustable coil members, the patent enables flexible configuration for different workpiece sizes without requiring complex overall reconfiguration. Each segment can be adjusted individually, simplifying the adaptation process.
3Productivity
If the coil pitch is reduced to increase heating intensity, then heating efficiency is improved, but temperature uniformity deteriorates due to excessive heating in certain regions
Solution Approach 1:
The patent segments the heating zone into a temperature increasing zone (with smaller coil pitch for higher heating intensity) and a soaking zone (with larger coil pitch for temperature equalization). This segmentation allows the system to achieve both high heating efficiency and temperature uniformity by applying different pitch configurations in different axial regions.
Solution Approach 2:
The patent applies different coil pitch characteristics to different regions along the axial direction. The temperature increasing zone uses tighter pitch for intensive heating, while the soaking zone uses wider pitch for gentle heat distribution, thereby achieving local optimization of both heating efficiency and temperature uniformity.
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 solution enables efficient inductive heating of workpieces to a target temperature with uniform temperature distribution across the circumference, reducing the effort required for coil pitch adjustments and accommodating workpieces of different dimensions.
Implementation Method 1
the workpiece is heated by high-frequency induction heating in the heating step
Implementation Method 2
the plurality of coil members 11, each having a coil portion 11a, are supported on a frame body 21 so as to be movable in an axial direction of the workpiece W relative to the frame body 21
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
Provided is a heat treatment apparatus (1), including: a heating unit (2), which is configured to inductively heat a workpiece (W) to a target temperature; and a drive mechanism, which is configured to move a plurality of the coaxially held workpieces (W) relative to the heating unit (2) being in an energized state in an axial direction of the workpiece (W), wherein the heating unit (2) includes: a plurality of coil members (11) respectively including a ring-shaped coil portion (11a) arranged coaxially with the workpiece (W) so as to be capable of surrounding the workpiece (W); and a frame body (21), which is configured to support each of the plurality of coil members (11) so as to be movable in the axial direction of the workpiece while maintaining the coaxial arrangement between the coil portions (11a).