Induction Heating Cable With Control Conductors

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Solution Overview

Problem

Induction heating systems face challenges in efficiently delivering heating currents to workpieces due to the distance between the power supply and the workpiece, making direct measurement of heating parameters infeasible and requiring improved cable designs to minimize leakage and enhance efficiency.

Innovation Solution

The induction heating extension cables incorporate control conductors within a protective outer layer, allowing for data and power transfer between the power supply and a remote device near the workpiece, while using a Litz cable arrangement and a coupler to efficiently couple conductors to both the power supply and heating cables, and include a second set of conductors for data/power transfer, which are electrically isolated and protected from physical damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Length of moving object

If the power supply is located at a substantial distance from the workpiece, then the heating system can accommodate large workpieces or require less frequent repositioning, but measuring heating parameters directly at the power supply becomes infeasible and efficiency decreases

Engineering Contradiction:

Improvedistance between power supply and workpieceVSAvoidmeasurement of heating parameters

Core Design Contradiction:

Length of moving objectVSMeasurement precision

Solution Approach 1:

A remote device is introduced as an intermediary between the power supply and workpiece. This remote device includes sensors that directly measure heating parameters at the workpiece location and communicates this data back to the power supply controller, enabling accurate measurement without requiring the power supply to be physically close to the workpiece.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The extension cable assembly is designed to perform multiple functions simultaneously: it delivers high-power induction heating current through the first set of conductors while also transmitting control signals and measurement data through the second set of conductors. This multi-functionality allows the system to maintain both power delivery and measurement capabilities over extended distances.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of operation

If conventional cables are used to deliver induction heating current over distance, then the system can operate remotely, but leakage increases and efficiency decreases

Engineering Contradiction:

Improveremote operation capabilityVSAvoidleakage

Core Design Contradiction:

Ease of operationVSLoss of energy

Solution Approach 1:

The patent replaces conventional electrical cable designs with a specialized extension cable assembly that uses Litz wire construction and optimized conductor geometry. This substitution reduces parasitic inductance and resistance, minimizing energy loss and leakage while maintaining remote operation capability. The cable design specifically addresses the electromagnetic characteristics needed for efficient induction heating power transmission.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Extent of automation

If control conductors are added to the cable assembly, then real-time monitoring and control become possible, but the cable complexity and manufacturing difficulty increase

Engineering Contradiction:

Improvereal-time monitoring and controlVSAvoidcable structure

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The cable assembly is segmented into distinct functional sections: a first set of conductors for high-power heating current delivery and a second set of conductors for control and measurement signals. This segmentation allows each conductor type to be optimized for its specific function while maintaining manageable overall cable complexity. The separate conductor groups can be manufactured and tested independently before final assembly.

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

This design enhances the efficiency of induction heating by minimizing leakage and allowing for real-time monitoring and control of heating processes, improving the induction heating process's reliability and precision by enabling data exchange and power delivery directly to the workpiece area.

Implementation Method 1

Induction heating extension cables deliver induction heating current between an induction heating power supply and an induction heating cable

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

the induction heating current-carrying conductors tightly coupled to reduce (e.g., minimize or eliminate) leakage and improve efficiency

Methodology Applied

Scientific EffectSkin effect mitigation: Skin Effect

Data Source

PatentEP3349542B1Induction heating cables including control conductors

Publication Date: 2021.11.17 ILLINOIS TOOL WORKS INC

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AI summary

Induction heating extension cables including control conductors are disclosed. An example cable assembly includes: a first plurality of conductors in a Litz cable arrangement; an outer protective layer configured to protect the plurality of conductors from physical damage; and a second plurality of conductors that are electrically isolated from the first plurality of conductors and are protected by the outer protective layer from physical damage.