Induction Heating Metal Transporter for Melting Plant

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current metal heating and transfer technologies in melting plants are inefficient, as they either heat materials unevenly, lead to material sticking and damage, or lack continuous control over the feeding process, resulting in prolonged melting cycles and increased complexity.

Innovation Solution

An apparatus combining a transporter device with an induction heating unit that uses electromagnetic induction to heat metal materials continuously and precisely, keeping them in a solid state, allowing for controlled feeding into a melting furnace.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If radiation heating burners are used to heat material during transport, then heating capability is improved, but material may melt and stick causing damage to transport system

Engineering Contradiction:

Improveheating capabilityVSAvoidmaterial sticking and damage

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The invention changes the heating parameters by using induction heating with controlled frequency and power to achieve uniform heating without excessive temperature that would cause melting and sticking. The heating parameters are precisely controlled to maintain material integrity while achieving efficient heating.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention replaces the mechanical/radiation heating system (burners) with an electromagnetic induction heating system. This substitution allows for more precise control of the heating process and eliminates the harmful effects of radiation heating that cause material sticking and damage to transport components.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Loss of time

If material is heated to high temperature during transport, then melting time is reduced, but material may melt and cause sticking

Engineering Contradiction:

Improvemelting cycle timeVSAvoidmaterial sticking

Core Design Contradiction:

Loss of timeVSObject-affected harmful factors

Solution Approach 1:

The invention applies continuous induction heating during the entire transport process, ensuring uniform and controlled heating of the material. This continuous heating action reduces the overall melting cycle time while maintaining precise temperature control to prevent material sticking and damage.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The invention optimizes heating parameters by using induction heating with controlled frequency and power distribution, achieving efficient heating that reduces melting cycle time without causing excessive temperature that would lead to material sticking.

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If loading baskets are used to transfer heated material, then transfer capability is improved, but direct uncontrolled feed causes temperature fluctuations in molten metal

Engineering Contradiction:

Improvetransfer capabilityVSAvoidtemperature stability

Core Design Contradiction:

Ease of operationVSStability of the object's composition

Solution Approach 1:

The invention merges the heating function and transport function into a single integrated system. The induction heating unit is directly integrated with the transport device, allowing material to be heated and transferred in a continuous, controlled manner without the temperature fluctuations caused by separate heating and transfer operations using loading baskets.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated system ensures continuous and controlled feeding of heated material into the melting furnace, maintaining stable temperature in the molten metal by eliminating the intermittent, uncontrolled feed that occurs with loading baskets.

Inventive Principle:

Principle #20Continuity of useful action

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 reduces melting cycle times, prevents material damage, and ensures continuous, controlled feeding, enhancing the efficiency and productivity of the melting process while maintaining the material in a solid state for safe transport.

Implementation Method 1

an induction heating unit (28) associated with the transporter device (13) and configured to heat by electromagnetic induction the materials moved by the transporter device (13)

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

The alternate electric current circulating in the coil generates an alternate induced magnetic field in the melting container and generates induced currents in any conductive metal material that is struck by the magnetic field induced. The currents induced in the conductive metal material in their turn generate heat energy due to the Joule effect.

Methodology Applied

Scientific EffectJoule effect: Joule Heating

Data Source

PatentUS10571194B2Apparatus for heating and transferring metal materials for a melting plant, and method for melting metal materials

Publication Date: 2020.02.25 DANIELI & C OFFICINE MECCANICHE SPA

AI summary

Apparatus to heat and transfer mainly metal materials to a melting furnace (12), the apparatus comprising a transporter device (13) configured to move the materials continuously to the melting furnace (12), and at least an induction heating unit (28) associated with the transporter device (13) and configured to heat by electromagnetic induction the materials moved in the transporter device (13), keeping them in a solid state.