Induction Heating Rotor with Permanent Magnets
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Solution Overview
Problem
Existing induction heating devices for metal objects, such as those used in the metal industry for shaping and extrusion, are complex, inefficient, and costly due to the need for additional motors and driving mechanisms to rotate electromagnets or move large objects within a magnetic field, and often fail to achieve uniform temperature profiles.
Innovation Solution
A device comprising a rotor with permanent magnets that both rotate within a varying magnetic field provided by a stator and induce eddy currents in the object to be heated, eliminating the need for additional motors and allowing for precise temperature control through the use of multiple rotating magnetic circuits and distance detection mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If electromagnets are used to provide varying magnetic field for induction heating, then the heating function is achieved, but additional motors and driving mechanisms are required to rotate the electromagnets or move objects, increasing device complexity
Solution Approach 1:
The patent combines the magnetic field generation function and the rotation function into a single rotor assembly with permanent magnets. The rotor is driven directly by the interaction with the stator's magnetic field, eliminating the need for separate motors and driving mechanisms. This merging of functions directly reduces device complexity while maintaining induction heating capability.
Solution Approach 2:
The rotor with permanent magnets serves multiple functions: it generates the varying magnetic field for induction heating and simultaneously rotates to create the necessary magnetic field variation. This multi-functionality eliminates the need for separate components, reducing overall device complexity.
2Ease of operation
If motors and driving mechanisms are added to rotate magnets or move objects, then the heating process can be controlled, but the device becomes more complex and expensive
Solution Approach 1:
The rotor is self-driven through the electromagnetic interaction between the rotor's permanent magnets and the stator's magnetic field. This self-service mechanism eliminates the need for external motors and driving mechanisms, reducing device complexity while maintaining operational control through magnetic field interaction.
3Power
If large heavy objects are moved in magnetic field for heating, then induction heating can be achieved, but safety arrangements and additional mechanisms are required, increasing complexity and cost
Solution Approach 1:
The patent replaces mechanical movement of heavy objects with a magnetic field-based system. Instead of physically moving large objects through magnetic fields, the rotor with permanent magnets rotates to create the necessary magnetic field variation, eliminating the need for complex safety arrangements and additional mechanisms.
4Temperature
If magnets are rotated around the object to be heated, then the object can be heated to desired temperature, but the heating is not uniform enough for specific temperature profiles
Solution Approach 1:
The patent uses a rotating rotor with permanent magnets that creates dynamically varying magnetic fields. The rotation speed and position can be controlled to achieve specific temperature profiles, such as warmer head and cooler tail for extrusion, providing precise temperature control and uniform heating.
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 simplifies the heating process, reduces material costs, and achieves more efficient and uniform heating with less material, enabling economical savings and precise temperature control for metal objects, particularly in extrusion processes.
Implementation Method 1
a stator for providing varying magnetic field arranged to interact with at least one permanent magnet of said at least one rotor and causing said at least one rotor to rotate
Implementation Method 2
at least one permanent magnet of said at least one rotor is arranged to provide varying magnetic field and eddy currents within the object when said at least one rotor is rotated so that said object is heated by the electromagnetic induction generated by said varying magnetic field and eddy currents
Implementation Method 3
at least one permanent magnet of said at least one rotor is arranged to provide varying magnetic field and eddy currents within the object
Data Source
AI summary
A device for heating an object by an electromagnetic induction comprises at least one rotor, and the rotor comprises at least one permanent magnet. The device also comprises a stator for providing varying magnetic field arranged to interact with at least one magnet of the rotor and causing said rotor to rotate around the axis. The magnets of said rotor is arranged to provide varying magnetic field and eddy currents within the object when said rotor is rotated so that said object is heated by the electromagnetic induction generated by said varying magnetic field and eddy currents.