Inductive Heating Coils for Uniform Workpiece Temperature
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Solution Overview
Problem
Existing induction heating methods for large, irregularly shaped workpieces, such as metal containers, are labor-intensive and prone to inconsistencies due to the time-consuming and error-prone installation of flexible coils, leading to inefficient heating, especially at container ends.
Innovation Solution
A system utilizing a plurality of coiled tubing assemblies that enclose both the shell face and end faces of the workpiece, with standardized coil spacing and support structures, to efficiently distribute heat uniformly across the workpiece, reducing installation time and improving heating consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If flexible coils are manually wrapped around large containers, then the heating can be applied to irregular shapes, but the installation is labor-intensive and time-consuming
Solution Approach 1:
The heating system is divided into multiple rigid coil assemblies, each designed to fit specific portions of the container (end faces and shell face). This segmentation allows pre-fabricated coils to be quickly installed without manual wrapping, reducing installation time while maintaining adaptability to the container's geometry through modular configuration.
2Ease of operation
If flexible coils are manually positioned, then coverage can be adjusted, but the spacing is inconsistent leading to non-uniform heating
Solution Approach 1:
The rigid coil assemblies are pre-fabricated with standardized spacing and geometry before installation. This preliminary action ensures that when the coils are installed on the container, they maintain consistent spacing and orientation, producing uniform heating patterns without requiring manual adjustment during installation.
3Productivity
If dedicated heating coils are designed for small workpieces, then heating efficiency is high, but the approach is not suitable for large containers
Solution Approach 1:
The system uses multiple rigid coil assemblies that can be configured to cover large container surfaces. Each assembly maintains the heating efficiency of dedicated coils while the modular segmented approach allows scaling to large container sizes by adding more assemblies in a standardized configuration.
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 approach significantly reduces coil installation time, enhances heating efficiency, and achieves uniform temperature profiles, ensuring effective decontamination of containers by providing consistent and precise heat application to all areas, including the challenging end faces.
Implementation Method 1
The induction technique creates heat by applying an induced magnetic field around the workpiece that creates resistance (and heat) in the workpiece
Implementation Method 2
the induction technique heats the workpiece by the result of hysteresis and eddy current losses in the workpiece
Implementation Method 3
the induction technique heats the workpiece by the result of hysteresis and eddy current losses in the workpiece
Implementation Method 4
The coil is typically made of copper tubing (or another material with good conductivity) and is cooled with a fluid such as water
Data Source
AI summary
A system for inductively heating a workpiece including a heating coil that surrounds the sides and ends of the workpiece, wherein the heating coil comprises a first coil assembly that encloses a first portion of the workpiece and a second coil assembly that encloses a second portion of the workpiece. A power supply is operatively connected to the first coil assembly and the second coil assembly.