Induction Heating Coil Segmentation for Uniform Metal Plate Temperature
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Solution Overview
Problem
Conventional induction heating systems face challenges in achieving uniform temperature distribution, particularly for thin and nonmagnetic metal plates, and struggle to efficiently heat plates with varying thickness and width, leading to overheating at the edge portions and difficulties in handling meandering plates.
Innovation Solution
An induction heating apparatus with a coil arrangement that deviates the front and back surface conductors in the lengthwise direction and includes magnetic cores positioned to cancel minor current loops, allowing for precise temperature control by adjusting the magnetic flux distribution across the metal plate, thereby preventing overheating and ensuring efficient heating of both magnetic and nonmagnetic materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the LF system is used for induction heating, then uniform temperature distribution is achieved, but thin plates and nonmagnetic materials cannot be heated effectively due to current penetration depth limitations
Solution Approach 1:
The induction coil is divided into multiple independent coil units arranged in the widthwise direction, allowing each unit to be independently controlled. This segmentation enables selective heating of different plate thickness regions and improves heating effectiveness for thin plates while maintaining temperature uniformity across the plate surface.
Solution Approach 2:
Different coil units are designed with different winding densities and turn numbers according to the local plate thickness requirements. Thinner plate regions use coils with higher winding density, while thicker regions use coils with lower density, achieving localized optimization of heating quality for both thin and thick plates simultaneously.
2Adaptability or versatility
If the TF system is used for induction heating, then both magnetic and nonmagnetic plates can be heated, but temperature distribution becomes less uniform and edge portions overheat
Solution Approach 1:
The coil units are positioned at different distances from the plate edge, with those nearer to edges having fewer turns and lower winding density, while central units have more turns and higher density. This local differentiation compensates for the edge heating effect, maintaining uniform temperature distribution while preserving the ability to heat both magnetic and nonmagnetic plates.
Solution Approach 2:
The system dynamically adjusts the excitation current distribution among different coil units based on real-time temperature feedback and plate position detection. This dynamic control enables the system to adapt to varying plate positions and maintain uniform temperature distribution regardless of whether the plate is magnetic or nonmagnetic.
3Productivity
If conventional induction coils are used, then heating efficiency is maintained, but it becomes difficult to handle meandering plates and vary plate width on continuously processing lines
Solution Approach 1:
The induction coil is divided into multiple independently controllable coil units that can be selectively activated or deactivated. This segmentation allows the system to adapt to varying plate widths by activating only the necessary coil units, and to track meandering plates by dynamically adjusting which units are engaged, maintaining heating efficiency while improving adaptability.
Solution Approach 2:
The system incorporates dynamic control mechanisms that adjust the excitation current distribution among coil units in real-time based on plate position and width variations. This dynamic adaptation enables continuous processing of plates with varying dimensions and meandering paths while maintaining high heating efficiency.
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 enables efficient heating of metal plates of varying thickness and width, maintains uniform temperature distribution, and effectively prevents overheating at the edge portions, allowing for high-quality product production while accommodating changes in plate dimensions and shape.
Implementation Method 1
a magnetic flux passes through the inside of the metal plate, and an electric current is induced about the magnetic flux. The metal plate is heated by the induced current.
Implementation Method 2
The metal plate is heated by the induced current.
Data Source
Figure 1~2
Figure 3~4
Figure 5(a)~5(b)
AI summary
An induction heating apparatus for controlling the temperature distribution for heating a metal plate irrespective if it has a small thickness, is magnetic or nonmagnetic, and capable of coping with a change in the width of the plate, or meandering of the plate. The apparatus heats a metal plate 1 by induction heating, which passes through the inside of induction coils 2, wherein in a vertical projected image of the conductors on the metal plate 1, the conductors 2a and 2b, parts of the induction coil, placed on the front surface side and the back surface side of the metal plate 1, the conductors 2a and 2b on the front surface side and the back surface side are arranged so as to be deviated from each other in the lengthwise direction of the metal plate 1, the edge portion of at least either the conductor 2a on the front surface side of the metal plate 1 or the conductor 2b on the back surface side thereof is arranged aslant or arcuately, and magnetic cores 10 are arranged at the outer sides of the induction coils 2.