Induction Heating Roll Rapid Temperature Control
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Solution Overview
Problem
Existing roll heating systems for plastic resin materials are inefficient in rapidly reaching and maintaining set temperatures, requiring excessive time to heat up and lacking effective temperature control to prevent overheating.
Innovation Solution
An induction heating roll device with an integrated induction heating coil and a cooling medium supply system that uses a mist-like cooling medium, controlled by a temperature sensor and control device to manage temperature within set limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a temperature controller with heating medium is used to heat the rolls, then the temperature can be controlled, but the heating time is excessively long (only 40°C/hr rate)
Solution Approach 1:
The patent replaces the conventional thermal conduction heating system (heating medium circulation) with an electromagnetic induction heating system. The induction heating coil generates a magnetic field that directly induces eddy currents in the roll, converting electromagnetic energy to thermal energy rapidly, achieving heating rates far exceeding the conventional 40°C/hr limit.
Solution Approach 2:
The induction heating system utilizes alternating current at high frequency to generate periodic magnetic fields that induce eddy currents in the roll. This periodic electromagnetic action enables rapid and efficient heating compared to the continuous thermal conduction process of conventional heating systems.
2Loss of time
If the roll temperature is increased rapidly to set temperature, then heating time is reduced, but the temperature may exceed the upper limit temperature
Solution Approach 1:
The patent incorporates temperature sensors that continuously monitor the roll temperature and feed this information back to the control system. Based on the feedback signal, the controller adjusts the induction heating power in real-time, enabling rapid heating while preventing temperature from exceeding the upper limit, thus maintaining both speed and precision.
Solution Approach 2:
The heating system transitions from static conventional heating to dynamic induction heating with real-time power adjustment. The induction heating coil can rapidly change heating intensity based on temperature feedback, allowing the system to adapt dynamically between rapid heating and temperature maintenance phases.
3Device complexity
If conventional heating medium is used, then the system is simple, but the temperature control precision and response speed are insufficient
Solution Approach 1:
The patent replaces the mechanical heating medium circulation system with an electromagnetic field-based induction heating system. This substitution eliminates the need for complex heating medium circulation infrastructure while achieving superior temperature control precision and faster response through direct electromagnetic energy coupling with the roll.
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 rapid heating of rolls to set temperatures and prevents overheating by efficiently supplying a cooling medium, significantly reducing heating time and maintaining temperature stability.
Implementation Method 1
an induction heating coil (25) provided inside of the rolling roll (5a) performs induction heating of the rolling roll (5a)
Implementation Method 2
since the cooling medium is supplied to the cooling medium flow channel formed inside of the roll by the cooling medium supply device, the temperature of the roll is able to be suppressed so as to be less than or equal to the upper limit temperature
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
An induction heating roll device includes first and second resin processing bodies which roll or knead the resin material by interposing the resin material between the first and the second resin processing bodies. At least one of the first and the second resin processing bodies is a roll 5a. An induction heating coil 25 which is provided inside of the roll 5a and a cooling medium supply device 27 which supplies a cooling medium to a cooling medium flow channel 37 which is formed inside of the roll 5a are further provided. The induction heating coil 25 performs induction heating of the roll 5a, and the cooling medium supply device 27 cools the heated roll 5a by supplying a cooling medium to the cooling medium flow channel 37.