Inductive Heating Coil Integrated in Ceramic Housing for Screw Machine
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Solution Overview
Problem
Existing screw machines for processing materials face challenges in achieving both high energy efficiency and mechanical stability, particularly in the heating zone, due to limitations in the design of inductive heating devices and material interactions.
Innovation Solution
The integration of an inductive heating coil within a non-magnetic and electrically non-conductive component, which is electromagnetically transparent, allows for closer winding arrangement to the treatment element shaft, enhancing energy efficiency and mechanical stability by eliminating hollow spaces and allowing for efficient energy input and force dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the coil is arranged close to the treatment element shaft to improve energy efficiency, then energy efficiency is improved, but mechanical stability deteriorates due to reduced material thickness
Solution Approach 1:
The housing portion is constructed as a composite structure combining a ceramic inner sleeve with a metal outer shell. The ceramic material provides electromagnetic transparency allowing close coil placement for high energy efficiency, while the metal outer shell provides mechanical strength and stability to compensate for the reduced material thickness in the heating zone.
Solution Approach 2:
The housing portion has different material properties in different regions: the inner sleeve in the heating zone is made of ceramic for electromagnetic transparency, while the outer shell is made of metal for mechanical strength. This local differentiation allows the structure to simultaneously achieve high energy efficiency and mechanical stability.
2Temperature
If hollow cross-sectional conductors are used to allow cooling ducts, then cooling capability is improved, but manufacturing complexity increases due to bending and soldering requirements
Solution Approach 1:
The cooling duct is merged with the housing portion structure itself rather than being a separate component. The cooling duct is formed as an integrated feature of the ceramic inner sleeve, eliminating the need for separate bending and soldering operations while maintaining effective cooling capability.
Solution Approach 2:
The traditional mechanical approach of bending flat copper material into hollow cross-sections and soldering joints is replaced by a ceramic material that can be formed into the required cooling duct geometry through manufacturing processes like 3D printing or molding, eliminating the need for complex mechanical forming and joining operations.
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 design improves energy efficiency and mechanical stability, enabling efficient heating and melting of materials with reduced mechanical forces and wear, while allowing for adjustable frequency operation to optimize energy input and penetration depth.
Implementation Method 1
an inductive heating device configured to form a heating zone with at least one coil, wherein the at least one coil surrounds the at least one treatment element shaft
Implementation Method 2
the at least one treatment element shaft comprises an electrically conductive material at least in the heating zone
Implementation Method 3
The inductive heating device provides an energy input into the treatment element shafts such that the temperature thereof increases as a result of said energy input
Implementation Method 4
at least one housing portion in the heating zone comprises a component, which is made of a non-magnetic and electrically non-conductive material
Implementation Method 5
at least one cooling duct is integrated in the component
Data Source
AI summary
A screw machine includes an inductive heating device for processing of material to be processed. The inductive heating device is used to heat the material in a heating zone. In the heating zone, at least one housing portion is made of an electromagnetically transparent material at least partly, the material being non-magnetic and electrically non-conductive, whereas at least one treatment element shaft is made of an electrically conductive material at least partly. The inductive heating device includes at least one coil formed integrally with a component of the at least one housing portion, in particular in such a way as to form a hybrid component. During the processing of the material, the inductive heating device generates an alternating magnetic field that produces eddy current losses in the at least one treatment element shaft, the eddy current losses leading to a temperature increase of the at least one treatment element shaft.