Induction Heating Coil with Protruding Conductor for Recessed Workpieces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing induction heating coils are ineffective for heating workpieces with recess portions along their longitudinal axis, as they cannot accommodate varying cross-sections or inwardly depressed areas, limiting their application to cylindrical workpieces with uniform cross-sections.
Innovation Solution
An induction heating coil with a conductor that surrounds the workpiece and features a protruding portion to face the recess, coupled with non-conductive support portions to maintain a constant gap, allowing for even heating of the recess portion by adjusting the position of the coil and workpiece axially.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional induction heating coil with a fixed coil structure is used, then it can heat cylindrical workpieces with uniform cross-sections, but it cannot accommodate workpieces with recess portions or varying cross-sections along the axial direction
Solution Approach 1:
The conductor is divided into multiple segments including a first conductor forming a first coil and a second conductor forming a second coil. The second conductor includes a protruding portion that can extend into the recess portion of the workpiece. This segmentation allows each conductor segment to serve specific heating zones, enabling the coil to accommodate workpieces with recess portions while maintaining manageable structural complexity.
Solution Approach 2:
The induction heating coil is designed with movable components that can adjust the position of the conductor relative to the workpiece. The protruding portion of the second conductor can be positioned to face the recess portion when needed, and the entire coil assembly can be moved axially to adjust the heating range. This dynamic adjustability enables the coil to adapt to different workpiece geometries including those with recess portions.
2Manufacturing precision
If the conductor is configured to surround the workpiece with a constant gap, then uniform heating can be achieved, but it is difficult to maintain the constant gap when the workpiece has varying cross-sections
Solution Approach 1:
The conductor is designed with different structural characteristics at different locations to maintain a constant gap. The protruding portion of the second conductor is specifically shaped to extend into the recess portion of the workpiece, while the main body of the conductor maintains its original configuration. This local adaptation allows the conductor to follow the contour of the workpiece and maintain a constant gap even when the workpiece has varying cross-sections, ensuring uniform heating.
Solution Approach 2:
Non-conductive support portions are introduced as intermediary elements to maintain the constant gap between the conductor and the workpiece. These support portions are provided between the first conductor and the second conductor, and they help maintain the spatial relationship between the conductor segments and the workpiece surface, ensuring uniform heating across varying cross-sections.
3Area of stationary object
If multiple conductors are used to heat different portions of the workpiece, then comprehensive heating coverage is achieved, but the device complexity increases
Solution Approach 1:
Multiple conductors (first conductor and second conductor) are merged into a single integrated induction heating coil assembly. The conductors are electrically connected in series, forming a unified electromagnetic field generation system. This merging approach provides comprehensive heating coverage for different portions of the workpiece including recess areas, while avoiding the complexity of multiple independent coil systems through coordinated design and series electrical connection.
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
Enables uniform heating of workpieces with recess portions along their longitudinal axis, ensuring effective induction current generation and heat distribution across the workpiece, including the recess and backside areas, even when the recess depth varies.
Implementation Method 1
an induction heating coil (101) having a conductor (110, 210) that surrounds the workpiece (30) around an axis of the workpiece (30), the conductor (110, 210) having a protruding portion (21) that protrudes inwardly to face the recess portion (31) of the workpiece (30)
Implementation Method 2
electric current flowing in the surrounding portions causes induced electric current to flow in the second conductor (210)
Data Source
Figure 1~2
Figure 3A~3C
Figure 4A~4D
AI summary
To heat a workpiece having a recess portion provided along a longitudinal axis of the workpiece, the workpiece is inserted into an induction heating coil, and the induction heating coil or the workpiece is along an axial direction of the workpiece. The induction heating coil has a conductor configured to surround the workpiece around the axis of the workpiece. The conductor has a protruding portion protruding inwardly to face the recess portion of the workpiece.