Induction Heating Head Feedback Control for Moving Weld Paths
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Solution Overview
Problem
Conventional induction heating methods for pre-heating weld paths, especially in pipe welding, face challenges with stationary welders and rotating pipes, as they require fixed heating devices and lack temperature and travel feedback for precise power control.
Innovation Solution
An induction heating system with a moveable induction heating head assembly, integrated temperature and travel sensors, and a connection box that allows for real-time feedback to adjust power output, enabling efficient pre-heating and post-heating without the need for an impedance matching transformer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional induction heating blankets or fixed heating devices are used for pre-heating weld paths, then heating can be achieved, but the system lacks flexibility for moving workpieces and requires complex impedance matching transformers
Solution Approach 1:
The patent applies the dynamics principle by making the induction heating head moveable rather than fixed. The heating head can track along the weld path on moving workpieces such as pipes, enabling the system to adapt to dynamic welding applications. This eliminates the need for complex impedance matching transformers that would be required with fixed heating devices, as the moveable head can maintain optimal coupling with the workpiece throughout the welding process.
2Measurement precision
If conventional pre-heating methods without temperature feedback are used, then heating can be applied, but precise temperature control and power adjustment are not achieved
Solution Approach 1:
The patent implements feedback by incorporating temperature sensors that continuously monitor the workpiece temperature during induction heating. This temperature feedback is transmitted to the control system, which automatically adjusts the power output of the induction heating head to maintain the desired temperature profile along the weld path. This ensures precise temperature control and prevents overheating or insufficient heating, eliminating the need for complex manual monitoring and adjustment systems.
3Measurement precision
If moveable induction heating heads with temperature and travel feedback are implemented, then precise temperature control is achieved, but device complexity increases
Solution Approach 1:
The patent applies the merging principle by integrating the temperature sensors, travel sensors, control electronics, and induction heating components into a single unified moveable heating head assembly. This consolidation eliminates the need for separate complex external monitoring and control systems, reducing overall system complexity while maintaining precise temperature control through integrated feedback mechanisms.
Solution Approach 2:
The patent implements self-service by designing the induction heating head to autonomously regulate its own operation through integrated temperature and travel feedback. The control system automatically adjusts power output based on real-time sensor data without requiring external intervention or complex external control systems, enabling the heating head to self-optimize its performance throughout the welding process.
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 system provides precise temperature control and efficient heat distribution along moving weld paths, ensuring effective filler metal binding and reducing the risk of cracks, while eliminating the need for transformers and enhancing operational flexibility.
Implementation Method 1
an induction heating head assembly (14) having a coil tuned to a power source (12) configured to induce heat in a workpiece (16)
Data Source
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AI summary
An induction heating system includes an induction heating head assembly configured to move relative to a workpiece. The induction heating system may also include a temperature sensor assembly configured to detect a temperature of the workpiece and/or a travel sensor assembly configured to detect a position, movement, or direction of movement of the induction heating head assembly relative to the workpiece, and to transmit feedback signals to a controller configured to adjust the power provided to the induction heating head assembly by a power source based at least in part on the feedback signals. In certain embodiments, the induction heating system may also include a connection box configured to receive the feedback signals, to perform certain conversions of the feedback signals, and to provide the feedback signals to the power source. Furthermore, in certain embodiments, the induction heating system may include an inductor stand assembly configured to hold the induction heating head assembly against the workpiece.