Induction Heating Roller Axial Temperature Uniformity
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Solution Overview
Problem
Induction heating rollers face inefficiencies in heating yarns due to non-uniform temperature distribution along the axial direction and high heat capacity, leading to unstable yarn quality.
Innovation Solution
Incorporating a heat leveling member with higher thermal conductivity in the axial direction and higher electric resistivity in the circumferential direction, which reduces the thickness of the roller main body and enhances induction heating, eliminating the need for a heat pipe to achieve uniform temperature distribution and efficient heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a thick roller main body is used to store heat, then heat storage capacity is improved, but heating efficiency and temperature uniformity deteriorate
Solution Approach 1:
The roller main body is segmented into two functional layers: an outer cylindrical part made of high thermal conductivity material for efficient heat transmission to the surface, and an inner heat storage part made of material with higher specific heat capacity for heat storage. This segmentation allows the system to simultaneously achieve rapid heating efficiency and adequate heat storage capacity without requiring excessive overall thickness.
Solution Approach 2:
Different regions of the roller main body are assigned different material properties optimized for their specific functions. The outer cylindrical part uses materials with high thermal conductivity (such as aluminum or copper alloys) to efficiently transmit heat to the roller surface, while the inner heat storage part uses materials with higher specific heat capacity (such as cast iron or steel) to store heat. This local quality differentiation resolves the contradiction between heating efficiency and heat storage capacity.
2Quantity of substance
If a thick roller main body is used, then heat storage capacity is improved, but temperature distribution uniformity deteriorates
Solution Approach 1:
The roller main body is divided into an outer cylindrical part and an inner heat storage part with distinct material properties. The outer part's high thermal conductivity ensures rapid and uniform heat distribution across the roller surface, while the inner part provides heat storage. This segmentation prevents the temperature non-uniformity that would occur in a uniformly thick roller while maintaining adequate heat storage capacity.
Solution Approach 2:
The outer cylindrical part is specifically designed with high thermal conductivity material to ensure uniform temperature distribution across the roller surface, while the inner heat storage part uses material with higher specific heat capacity. This local quality assignment directly addresses the temperature uniformity issue by placing the right material properties in the right locations.
3Quantity of substance
If induction heating is applied to a thick roller main body, then heat storage is improved, but heating time increases
Solution Approach 1:
The roller main body is segmented into an outer cylindrical part for rapid heating and an inner heat storage part. The outer part's high thermal conductivity allows induction heating to quickly raise the roller surface temperature, while the inner part gradually stores this heat. This segmentation dramatically reduces the heating time compared to heating a uniformly thick roller while still achieving adequate heat storage capacity.
Solution Approach 2:
The outer cylindrical part uses high thermal conductivity material to enable rapid heat response to induction heating, reducing the time required to reach operating temperature. The inner heat storage part uses material with higher specific heat capacity to store the generated heat. This local quality differentiation directly reduces heating time while maintaining heat storage capacity.
4Stability of the object's composition
If a jacket chamber with heat pipe is added to uniformize temperature, then temperature uniformity is improved, but device complexity and heat capacity increase
Solution Approach 1:
The complex jacket chamber and heat pipe system is extracted and replaced by a simpler segmented roller main body structure. By dividing the roller into an outer cylindrical part and an inner heat storage part with appropriate material properties, the patent achieves temperature uniformity through material selection and structural segmentation alone, eliminating the need for additional jacket chambers and heat pipes.
Solution Approach 2:
The segmented roller main body structure serves multiple functions simultaneously: the outer cylindrical part provides efficient heat transmission and temperature uniformity, while the inner heat storage part provides heat storage capacity. This multi-functional integration eliminates the need for separate temperature control systems like jacket chambers and heat pipes, reducing device complexity.
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
The solution results in a more efficient and uniform heating of the roller surface, reducing the heat capacity and facilitating faster temperature increase, thereby improving yarn quality and reducing the weight of the induction heating roller.
Implementation Method 1
an oscillating magnetic field is generated by a coil 32 through electromagnetic induction
Implementation Method 2
the oscillating magnetic field induces an eddy current in the outer cylindrical part 33, so that the outer cylindrical part 33 is heated by Joule heating
Implementation Method 3
heat conductivity of the heat leveling member being higher than heat conductivity of the outer cylindrical part in an axial direction
Data Source
Figure 1
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Figure 3
AI summary
Both uniformization of temperature distribution on the roller surface in the axial direction and effective heating of the roller surface are achieved. In an induction heating roller 30 including: a coil 32; a roller main body 31 having an outer cylindrical part 33 which is cylindrical in shape and is provided on an outer side in a radiation direction of the coil 32; and a heat leveling member 36 provided on the outer side in the radial direction of the coil 32 and on an inner side in the radial direction of the outer cylindrical part 33 and being in contact with an inner circumferential surface of the outer cylindrical part 33, heat conductivity of the heat leveling member 36 is higher than heat conductivity of the outer cylindrical part 33 in an axial direction, and electric resistivity of the heat leveling member 36 is higher than electric resistivity of the outer cylindrical part 33 in a circumferential direction.