Liquid-Cooled Induction Coil Preheating for Uniform Weld Temperature
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing preheating devices for welding are ineffective and inefficient, and they struggle to maintain minimal temperature variation throughout the welding process.
Innovation Solution
A device comprising a liquid-cooled induction coil, a power supply unit, and a cooling unit, which creates a magnetic field to generate eddy currents in the workpiece, allowing for precise control of heat energy transfer and minimal temperature variation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional preheating devices (induction heaters, electrical resistance heaters, or torches) are used to heat the workpiece, then the workpiece can be preheated to a desired temperature, but the temperature distribution becomes uneven and the process is inefficient
Solution Approach 1:
The induction coil is positioned to create a localized magnetic field that generates eddy currents specifically in the region requiring preheating. This localized heating approach ensures uniform temperature distribution in the target area while avoiding overheating adjacent regions, directly resolving the temperature distribution uniformity problem
Solution Approach 2:
The patent replaces conventional mechanical heating methods (torches, resistance heaters) with electromagnetic induction heating. The induction coil generates a magnetic field that induces eddy currents within the workpiece, creating internal heat generation rather than external heat transfer. This substitution eliminates the temperature gradients and inefficiencies associated with external heat sources
2Temperature
If conventional preheating devices are used, then heating can be achieved, but energy efficiency is poor and excessive energy is lost
Solution Approach 1:
The patent replaces external heat transfer mechanisms (radiation, conduction from torches or resistance heaters) with electromagnetic induction that generates heat internally within the workpiece through eddy currents. This internal heat generation dramatically improves energy efficiency by eliminating the energy losses associated with external heat transfer, directly addressing the energy efficiency problem
Solution Approach 2:
The induction heating system enables the workpiece to heat itself through internally generated eddy currents rather than relying on external heat sources. The workpiece's own electromagnetic properties are utilized to convert electromagnetic energy directly into thermal energy within the material, eliminating energy losses to the surrounding environment and improving overall energy efficiency
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 device enables effective and efficient preheating of workpieces to a desired temperature with minimal temperature variation, ensuring high welding quality by controlling the heat energy transferred.
Implementation Method 1
An induction heater comprises induction coils for creating a magnetic field that generates eddy currents within the workpiece, thus heating the workpiece internally
Implementation Method 2
induction coils for creating a magnetic field that generates eddy currents within the workpiece, thus heating the workpiece internally
Implementation Method 3
An induction heater comprises induction coils for creating a magnetic field that generates eddy currents within the workpiece, thus heating the workpiece internally
Implementation Method 4
a cooling unit configured to convey cooling liquid through the liquid-cooled induction coil
Data Source
AI summary
The present invention relates to a device and a method for preheating a workpiece to be welded. The device comprises a liquid-cooled induction coil arrangeable in connection with the workpiece, a power supply unit configured to supply AC power to the liquid-cooled induction coil, and a cooling unit configured to convey cooling liquid through the liquid-cooled induction coil. The present invention also relates to a welding system.