Induction Coil with Dynamically Variable Geometry

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Solution Overview

Problem

Solenoidal type induction coils with fixed geometry are limited in accommodating workpieces of varying dimensions, leading to interruptions in the welding or heating process due to changes in workpiece dimensions, as they cannot adjust to accommodate different exterior dimensions without disrupting power or cooling flow.

Innovation Solution

The induction coil features a dynamically variable geometry achieved through an adjustable coil segment assembly that can change its interior cross-sectional dimension in response to changes in workpiece dimensions, allowing continuous welding or heating without interruptions by adjusting between closed and opened segments positions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the induction coil has fixed geometry, then the coil structure is simple and stable, but it cannot accommodate workpieces of varying dimensions, leading to process interruptions

Engineering Contradiction:

Improveaccommodation of varying workpiece dimensionsVSAvoidcoil geometry adjustment mechanism

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The induction coil incorporates adjustable coil segments that can dynamically change their position and configuration to adapt to different workpiece dimensions. The coil geometry transitions from fixed to variable, allowing the coil to accommodate a range of workpiece sizes without requiring multiple dedicated coils, thus resolving the contradiction between adaptability and device complexity.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The induction coil is divided into multiple adjustable segments that can be independently positioned. This segmentation allows the coil to be reconfigured for different workpiece dimensions by adjusting individual segments, providing versatility while maintaining a relatively simple overall structure compared to completely variable geometry systems.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If the coil geometry is changed to accommodate different workpiece dimensions, then adaptability improves, but the system complexity and adjustment time increase

Engineering Contradiction:

Improvecoil geometry variabilityVSAvoidtime for geometry adjustment

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The coil segments are pre-positioned in standard configurations corresponding to common workpiece dimensions. This preliminary arrangement allows for rapid adjustment between standard sizes without requiring complex real-time calculations or adjustments, reducing the time penalty associated with geometry changes while maintaining high adaptability.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If the induction coil uses fixed geometry optimized for specific dimensions, then welding or heating efficiency is maximized for those dimensions, but process interruptions occur when workpiece dimensions change

Engineering Contradiction:

Improvecontinuous welding or heating processVSAvoidelectric power and cooling medium flow continuity

Core Design Contradiction:

ProductivityVSUse of energy by stationary object

Solution Approach 1:

The dynamic adjustability of the coil segments enables the system to maintain optimal welding or heating efficiency across varying workpiece dimensions. By adjusting the coil geometry to match the current workpiece size, the system avoids process interruptions and maintains continuous operation, thereby improving productivity without significant additional energy consumption compared to fixed-geometry systems that would require shutdowns for reconfiguration.

Inventive Principle:

Principle #15Dynamics

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 continuous induction welding or heating of workpieces with varying dimensions without power or cooling disruptions, ensuring process line speed is maintained by dynamically adjusting the coil geometry to match the workpiece dimensions, thus accommodating a range of workpiece sizes within the solenoidal induction coil.

Implementation Method 1

electric induction welding or heating of a workpiece by passing the workpiece through at least one turn of a solenoidal induction coil

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS11013072B2Induction coil with dynamically variable coil geometry

Publication Date: 2021.05.18 THERMATOOL CORP

AI summary

A solenoidal induction coil with dynamically variable coil geometry is provided for inductively welding or heating continuous or discontinuous workpieces passing through the solenoidal induction coil in a process line. The coil geometry can change, for example, as the outer dimension of the workpiece passing through the solenoidal induction coil changes or as non-continuous workpieces pass through the solenoidal induction coil in an induction heating or welding process line.