Induction-Heated Tool Plate for Faster Flatbed Embossing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional flat bed embossing machines require lengthy heating times for embossing tools, leading to reduced productivity and increased energy costs, with existing electrical resistance heaters causing unnecessary heating of machine parts and affecting embossing accuracy.
Innovation Solution
The implementation of an induction heating appliance that uses a magnetic alternating field to directly heat the tool plate and embossing tools, reducing heating time and energy consumption by minimizing unnecessary heating of machine parts, with a ferromagnetic tool plate and strategically designed inductors and field conducting elements to optimize heating efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If electrical resistance heaters are used to heat embossing tools, then the embossing tools can be heated to operating temperature, but the heating time becomes excessively long (5-6 hours)
Solution Approach 1:
The patent replaces electrical resistance heating with induction heating technology. The induction heating device generates a magnetic field that directly induces eddy currents in the embossing tools, converting electromagnetic energy directly into heat within the tool itself rather than through thermal conduction from a heater. This substitution of heating mechanism reduces heating time from 5-6 hours to approximately 1 hour while achieving the required operating temperature.
Solution Approach 2:
The induction heating device operates by applying periodic alternating magnetic fields at specific frequencies (typically 20-100 kHz) to the embossing tools. This periodic electromagnetic action continuously induces eddy currents that generate heat efficiently, enabling rapid temperature rise compared to continuous thermal conduction from resistance heaters.
2Temperature
If electrical resistance heaters are used to heat embossing tools, then the tools reach operating temperature, but unnecessary machine parts are also heated causing thermal expansion and affecting embossing accuracy
Solution Approach 1:
The induction heating device is designed to generate magnetic fields that are highly localized to the embossing tools only. The heating zones are precisely controlled to affect only the tool plates and embossing tools, leaving other machine components such as the press frame, bed, and mechanical linkages at their original temperatures. This localized heating prevents unwanted thermal expansion in critical positioning components, maintaining embossing accuracy.
Solution Approach 2:
The patent introduces magnetic field coupling as an intermediary mechanism between the power source and the embossing tools. The induction heating device uses magnetic fields as the energy transfer medium, which can be precisely controlled and confined to specific zones. This intermediary allows selective heating of only the ferromagnetic embossing tools without transferring thermal energy to non-magnetic machine parts, thereby preserving dimensional stability and embossing precision.
3Temperature
If electrical resistance heaters are used for heating, then embossing tools reach operating temperature, but energy consumption becomes excessive
Solution Approach 1:
The patent replaces inefficient thermal conduction heating with efficient electromagnetic induction heating. The induction heating system converts electrical energy directly into heat within the embossing tools through induced eddy currents, achieving much higher energy efficiency. The system can heat the tools to operating temperature in approximately 1 hour compared to 5-6 hours with resistance heaters, reducing total energy consumption by about 80% while delivering the same thermal result.
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 significantly reduces heating time to less than one hour, enhances temperature control precision, and reduces energy consumption while maintaining embossing quality, allowing for more demanding tasks and minimizing machine part heating.
Implementation Method 1
a heating appliance, in particular an induction heating appliance, for inductively heating the tool plate
Implementation Method 2
The induction heating appliance is designed such that a magnetic alternating field can be applied in the tool plate
Data Source
AI summary
The invention relates to a flat bed embossing machine (1) comprising a tool plate (20) with a tool side (36) for receiving at least one embossing tool and with a tool plate rear side (35) which lies opposite the tool side (36), further a base plate (10) with a tool plate side (12) which faces the tool plate rear side (35) and with a base plate rear side (11) which is lies opposite the tool plate side (12), for transmitting an embossing force which is exerted upon the tool plate (20), between the tool plate side (12) and the base plate rear side (11), as well as an induction heating appliance (3) for heating the at least one embossing tool (23). The induction heating appliance (3) comprises an inductor (16), the design of which and its arrangement between the tool plate side (12) and the base plate rear side (11) being such that a magnetic alternating field (19) which on the tool plate side (12) reaches beyond the base plate (19) and is for the inductive heating of an inductively heatable tool plate (20) can be produced beyond of the tool plate side (12) and outside the base plate (10).