Induction Heating Device for Non-Round Cams
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Solution Overview
Problem
The thermal joining of non-round cams to camshafts is challenging due to uneven heating, leading to non-round joints and distortion, as existing symmetrical heating devices cannot effectively heat asymmetrical components like cams without causing temperature imbalances and hardness issues.
Innovation Solution
A heating device with inner and outer induction coils, along with adjustable elements that influence the magnetic field, ensures even heating by shielding or intensifying the magnetic field in thinner or thicker regions, allowing for uniform temperature distribution across non-round components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If symmetrical induction coils are used for heating non-round cams, then the heating device structure is simple, but the heating uniformity deteriorates causing non-round joints and distortion
Solution Approach 1:
The patent introduces asymmetrical shielding elements positioned at specific locations around the induction coil to create non-uniform magnetic field distribution. These elements selectively block or redirect magnetic flux to different regions of the cam, ensuring that thinner regions receive less heating while thicker regions receive more heating, thereby achieving uniform overall heating of the non-round component
Solution Approach 2:
The shielding elements act as intermediary components between the symmetrical induction coil and the non-round cam. These intermediaries modify the magnetic field path and intensity distribution, enabling a simple symmetrical coil to achieve the heating effect of a complex asymmetrical coil without the associated complexity and cost
2Manufacturing precision
If asymmetrically shaped coils are used to heat non-round cams evenly, then the heating uniformity improves, but the device complexity and cost increase
Solution Approach 1:
Instead of making the coil itself asymmetrical, the patent introduces asymmetrical shielding elements that create the necessary field asymmetry. This approach achieves the heating uniformity of asymmetrical coils while maintaining the simplicity and low cost of symmetrical coils
Solution Approach 2:
The shielding elements are divided into multiple discrete segments or zones, each positioned to control the magnetic field in specific regions of the cam. This segmentation allows independent optimization of heating in different areas without requiring a completely custom-designed asymmetrical coil
3Speed
If higher temperatures are applied to the base circle region, then the heating speed improves, but the hardness deteriorates due to tempering effect
Solution Approach 1:
The shielding elements are strategically positioned to create local variations in magnetic field intensity. In the base circle region, the shielding elements reduce magnetic flux density, thereby reducing heating rate and preventing excessive temperature rise that would cause tempering and hardness loss. In thicker regions, the shielding elements allow or concentrate magnetic flux to maintain adequate heating rates
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 enables even heating of non-round components, preventing distortion and maintaining hardness, while eliminating the need for complex and expensive coils, ensuring a high-quality thermal joining process.
Implementation Method 1
during inductive heating of the cams
Implementation Method 2
heating device for heating non-round (otherwise referred to as 'non-circular'), hollow components, such as for example cams
Implementation Method 3
at least one element influencing a magnetic field forming during the operation of the heating device is positioned between the inner/outer induction coil and the component to be heated
Data Source
AI summary
A heating device for heating a hollow component may include at least one inner induction coil and at least one outer induction coil, each configured to be heated. At least one element may be configured to influence a magnetic field formed between the inner and the outer induction coil during the operation of the heating device. The element may be arranged between the inner and the outer induction coils. Regions of the hollow component may be thinner and the thinner regions may be configured to heat more quickly than the remaining thicker regions. The thinner and thicker regions of the component may allow even heating of the component to be achieved.