Permanent Magnet Induction Heater with Air Cooling

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Solution Overview

Problem

Existing induction heating devices for non-ferromagnetic billets face inefficiencies, high costs, and complexity, limiting their suitability for series production.

Innovation Solution

A device comprising a tubular body with alternately arranged permanent magnets and a cooling system that uses air flow to prevent heat transfer from the billet to the magnets, combined with a refractory casing to obstruct heat flow and a rotating mechanism to induce currents in the billet, achieving efficient heating through the Joule effect.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If traditional induction heating with powered inductors is used, then heating can be achieved, but efficiency does not exceed 50%

Engineering Contradiction:

Improveheating efficiencyVSAvoidpower consumption

Core Design Contradiction:

Loss of energyVSPower

Solution Approach 1:

The patent replaces the traditional powered inductor system with a mechanical rotation system. Permanent magnets are arranged in a ring and rotated relative to the billet, using mechanical motion to generate the magnetic field needed for induction heating. This substitution eliminates the need for complex powered inductors and achieves higher efficiency by directly coupling mechanical energy to the heating process through the Joule effect.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Loss of energy

If permanent magnets are used for induction heating, then efficiency improves, but heat transfer from billet to magnets causes overheating of magnets

Engineering Contradiction:

Improveheating efficiencyVSAvoidmagnet temperature

Core Design Contradiction:

Loss of energyVSTemperature

Solution Approach 1:

The patent introduces a refractory material as an intermediary thermal barrier between the heated billet and the permanent magnets. This refractory lining prevents direct heat transfer from the hot billet to the magnets, protecting them from overheating while allowing the magnetic field interaction to continue effectively for induction heating.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent employs a cooling system using air flow to remove heat from the permanent magnets. Air is circulated through channels or directly over the magnets to carry away heat that is not blocked by the refractory barrier, maintaining the magnets at operational temperatures despite the high-temperature heating process.

Inventive Principle:

Principle #29Pneumatics and hydraulics

3Productivity

If series production is implemented, then productivity increases, but complexity and cost of the heating device must be reduced

Engineering Contradiction:

Improveseries production capabilityVSAvoiddevice complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent divides the heating device into modular segments: a ring of discrete permanent magnets arranged in segments around the billet, with refractory material divided into manageable sections. This segmentation allows for easier assembly, maintenance, and scaling of the system for series production, reducing overall device complexity while maintaining heating effectiveness.

Inventive Principle:

Principle #1Segmentation

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 solution enhances efficiency, reduces costs, and simplifies the process while maintaining high reliability and versatility, effectively overcoming the limitations of previous technologies by minimizing heat transfer to the magnets and utilizing air flow for cooling.

Implementation Method 1

a magnetic field produced by permanent magnets moves with respect to the metal billet, creating induced currents that circulate within the metal conductor material

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

heating it by the Joule effect

Methodology Applied

Scientific EffectJoule effect: Joule Heating

Implementation Method 3

a cooling system for said permanent magnets integrally carried by said tubular body and suitable for feeding cooling air flows between adjacent permanent magnets

Methodology Applied

Scientific EffectConvection cooling: Convection

Implementation Method 4

a casing made of refractory material suitable to house said billet and able to obstruct the flow of heat from said billet heated by the Joule effect towards said permanent magnets

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS10462855B2Device for induction heating of a billet

Publication Date: 2019.10.29 INOVA LAB SRL

AI summary

A device for the induction heating of a billet of metal of high electrical conductivity has: a tubular body supporting a plurality of permanent magnets arranged inside the tubular body, angularly spaced apart from each other and arranged so as to be alternated with opposite polarities. The device also has a support for the billet that is arranged inside the tubular body and faces the magnets. The device also has a motor adapted to rotate the tubular body with respect to the billet in order to induce currents in the billet that circulate within the metal material, obtaining the heating of the billet by the Joule effect. An integral cooling system for the permanent magnets is provided, this being carried by the tubular body and suitable for feeding cooling air flows between adjacent permanent magnets.