Induction Heating Device for Functional Elements
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Solution Overview
Problem
The existing methods for heating functional elements on a shaft, such as cams, require significant energy due to the need to heat all components, including holding balconies, which increases production costs and inefficiency.
Innovation Solution
The use of induction heating specifically targets the functional elements to be jointed, with individually adjustable accommodation elements and induction coils, allowing for localized and precise heating without heating unnecessary components, and is integrated into a rotary transfer system with distinct workstations for efficient energy use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional heating methods are used to heat functional elements on a shaft, then all components including holding balconies are heated, but this results in excessive energy consumption and increased production costs
Solution Approach 1:
The patent applies local quality by using individual accommodation elements with induction coils that can be independently controlled. Each accommodation element heats only its assigned functional element through localized induction heating, rather than heating all components uniformly. This selective heating approach significantly reduces energy consumption while achieving the required heating temperature for the functional elements.
Solution Approach 2:
The heating system is segmented into multiple independent accommodation elements, each with its own induction coil. This segmentation allows independent control of heating for each functional element, enabling the system to heat only the necessary components without wasting energy on holding balconies or other non-essential parts.
2Manufacturing precision
If holding balconies are heated along with functional elements, then uniform heating is achieved, but unnecessary components are also heated causing energy waste
Solution Approach 1:
Each accommodation element provides localized heating with uniform temperature distribution across its assigned functional element. The induction coil in each accommodation element is positioned to ensure uniform heating of the specific functional element without affecting adjacent components or holding balconies, thus achieving heating uniformity without energy waste.
Solution Approach 2:
The heating function is extracted from a global heating system and assigned to individual accommodation elements. Each accommodation element independently heats its specific functional element, separating the heating function from the holding balconies and other non-essential components, thereby eliminating energy waste on unnecessary parts.
3Use of energy by moving object
If individual accommodation elements with induction coils are used for selective heating, then energy consumption is reduced, but device complexity increases
Solution Approach 1:
The accommodation elements serve multiple functions: they hold the functional elements during transport and simultaneously provide localized induction heating when needed. This multi-functionality reduces the need for separate heating devices, thereby limiting the increase in device complexity while achieving energy efficiency through selective heating.
Solution Approach 2:
The holding and heating functions are merged into a single accommodation element structure. Each accommodation element combines the mechanical support function with an integrated induction coil for heating, eliminating the need for separate heating equipment and reducing overall system complexity despite the added heating capability.
4Ease of operation
If holding balconies are moved apart in loading and unloading stations, then gripping of functional elements is facilitated, but device complexity increases
Solution Approach 1:
The holding balconies are designed to be dynamically adjustable in position, allowing them to move apart during loading and unloading operations to facilitate easy gripping of functional elements. During the heating process, the balconies return to their compact positions. This dynamic adjustment provides operational ease while maintaining a compact overall device structure.
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 approach results in a substantial energy savings by heating only the functional elements, reducing production costs and improving the operational sequence, while ensuring uniform heating and flexibility for different-sized components.
Implementation Method 1
the heating of the functional elements that is normally employed requires a large amount of heating energy
Implementation Method 2
which device comprises an individual accommodation element for each functional element to be heated
Data Source
AI summary
A device for heating a plurality of functional or receiving elements, such as a cam, balancing mass, gearwheel and/or a bearing, may include a plurality of holding balconies disposed above one another along an axis each associated with a respective receiving element, a plurality of workstations includes a loading station, a heating station and an unloading station, and an induction heating device including a plurality of accommodation elements. The plurality of holding balconies may be individually movable in an axial direction of an axis, and/or having a greater spacing in the axial direction with respect to one another in the loading station and/or the unloading station than in the heating station. The plurality of accommodation elements may be jointly adjustable in the axial direction.