Induction Heating Device with Segmented Winding for Uniform Temperature
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Solution Overview
Problem
Industrial heating systems struggle to achieve homogeneous temperature distribution across surfaces during adhesive or sealing processes, leading to inefficiencies and potential hotspots.
Innovation Solution
An induction heating device with a surface inductor and magnetic yoke, featuring an induction coil with uneven winding and additional local windings, ensures constant power input per area, optimizing magnetic field coupling for uniform temperature distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional induction heating systems are used, then heating can be achieved, but homogeneous temperature distribution across large surfaces cannot be achieved
Solution Approach 1:
The induction coil is divided into multiple independently controllable winding sections (first, second, third winding sections) along the longitudinal direction. Each section can be controlled separately to optimize heating distribution across different areas of the large surface, enabling homogeneous temperature distribution by adjusting power allocation to each segment.
Solution Approach 2:
Different winding sections are designed with different turn densities (windings per 100mm) to create locally optimized magnetic field coupling. The first winding section has higher turn density for strong coupling regions, while the second and third sections have lower turn density for weak coupling regions, achieving homogeneous heating across the entire large surface.
2Temperature
If uniform winding density is used in the induction coil, then manufacturing is simple, but magnetic field coupling is non-uniform causing hotspots
Solution Approach 1:
The induction coil employs non-uniform winding density distribution with different turn densities in different longitudinal sections. This local variation in winding parameters optimizes magnetic field coupling strength across different areas, eliminating hotspots and achieving uniform temperature distribution while maintaining reasonable manufacturing complexity through standardized winding patterns in each section.
3Temperature
If additional windings are added to improve field coupling, then heating uniformity improves, but device complexity increases
Solution Approach 1:
The inductor is segmented into multiple winding sections with different turn densities arranged in parallel. This segmentation allows independent optimization of each section's coupling strength without requiring complex additional components, achieving improved heating uniformity through a relatively simple extended winding structure.
Solution Approach 2:
Instead of adding complexity in the radial direction, the solution extends the winding structure in the longitudinal direction with multiple sections having different turn densities. This dimensional approach allows optimization of field coupling across the surface area without increasing radial complexity, maintaining a compact overall structure.
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 achieves a homogeneous temperature field with tolerances of less than ±5%, preventing hotspots and ensuring consistent heating across the radiator surface.
Implementation Method 1
An induction heating device with a surface inductor and magnetic yoke, featuring an induction coil with uneven winding and additional local windings
Implementation Method 2
The alternating electromagnetic field of the induction coil, when alternating voltage is applied to the induction coil, induces eddy currents in the heating element
Implementation Method 3
a magnetic yoke for guiding the magnetic field generated or generateable by the induction coil
Implementation Method 4
Due to remagnetization losses and ohmic losses caused by the eddy currents, the power transferred to the heating element is converted into heat
Implementation Method 5
ohmic losses caused by the eddy currents, the power transferred to the heating element is converted into heat
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates, inter alia, to an induction heating device (10) for industrial purposes or industrial applications. The induction heating device (10) is designed with at least one surface inductor having an induction coil (16) that can be supplied with alternating voltage, and with a heating element (12) that can be heated by the surface inductor and that has a surface facing the surface inductor, and with a magnetic yoke (14) for guiding the magnetic field generated or generable by the induction coil (16), wherein the induction coil (16) and the magnetic yoke (14) are designed such that a constant power input per unit area is applied to the surface of the heating element (12) facing the surface inductor for heating the heating element (12), and a homogeneous temperature field is generated or generable in the heating element over the surface facing the surface inductor.