Inductive Hot Crimping With Coil Heating to Cut Electrode Wear
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Solution Overview
Problem
Existing fusing technologies require high currents, leading to indenter oxidation and frequent replacement, low energy conversion efficiency, and difficulty in automated processes due to manual operation and impurities affecting temperature control.
Innovation Solution
An inductive thermo-crimping apparatus using a magnetic conductor and inductive heating coil to heat the workpiece via electromagnetic induction, eliminating the need for electrodes and manual scraping, with a movable punch for improved pressing quality and reduced material wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If high current is used to heat the workpiece, then heating effect is improved, but indenter oxidation and damage occur frequently
Solution Approach 1:
An inductive heating coil is introduced as an intermediary device to generate heat through electromagnetic induction. The coil creates a magnetic field that induces eddy currents in the workpiece, heating it without direct contact. This eliminates the need for high current through the indenter, preventing oxidation and extending indenter life while achieving effective workpiece heating.
Solution Approach 2:
The patent replaces the direct electrical contact heating mechanism (mechanical/electrical system) with inductive heating (electromagnetic field system). Instead of passing current through the indenter-workpiece contact, an alternating magnetic field from the inductive coil induces currents within the workpiece itself, achieving heating without mechanical contact and associated damage.
2Temperature
If high current is used for heating, then heating efficiency is improved, but energy conversion efficiency decreases due to low resistance
Solution Approach 1:
The patent substitutes direct resistive heating through low-resistance indenter contact with inductive heating. The inductive coil generates an alternating magnetic field that induces eddy currents directly within the workpiece material. Since the workpiece itself has appropriate resistance, energy conversion efficiency is improved while achieving effective heating.
Solution Approach 2:
The patent changes the heating mechanism from external contact heating to internal induction heating. By generating eddy currents within the workpiece, the system utilizes the workpiece's own electrical resistance for heating, optimizing energy conversion efficiency compared to the low-resistance indenter contact method.
3Manufacturing precision
If manual scraping is performed to remove impurities, then temperature control is improved, but production cost increases
Solution Approach 1:
The patent replaces manual mechanical scraping with inductive heating. The inductive coil heats the workpiece through electromagnetic induction without requiring physical contact or surface preparation. This eliminates the need for manual scraping operations, reducing labor costs and production complexity while maintaining consistent heating and temperature control.
Solution Approach 2:
The inductive heating system provides self-contained heating capability that does not require preliminary surface preparation or manual intervention. The electromagnetic field directly penetrates and heats the workpiece regardless of surface impurities, making the process self-sufficient and eliminating additional manual scraping steps.
4Reliability
If continuous squeezing is applied to ensure good contact, then circuit connection is improved, but workpiece deformation occurs and size control becomes difficult
Solution Approach 1:
The patent replaces mechanical contact-based heating with inductive heating. The inductive coil generates an electromagnetic field that penetrates and heats the workpiece without requiring physical contact or continuous squeezing. This eliminates workpiece deformation and size control issues while maintaining reliable heating and processing.
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 reduces material wear, increases energy efficiency, and enables automated processes with uniform heating, improving the quality and efficiency of the crimping process while minimizing energy waste and production costs.
Implementation Method 1
The heating part C has an inductive heating coil 801... When the inductive heating coil 801 is energized, a magnetic field will be generated. The magnetic field induces an Eddy current in the crimping body W to be heated, so as to the crimping body W is to be heated.
Implementation Method 2
The magnetic field induces an Eddy current in the crimping body W to be heated, so as to the crimping body W is to be heated
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
An inductive thermo-crimping apparatus is provided, which is provided for crimping a crimping body which is formed by the contact of the connecting body and the to-be-joined member. The inductive thermo-crimping apparatus includes a driving part, a stamper part, and a heating part, the driving part is connected to the stamper part, and the heating part is fixedly connected to the driving part. After the heating part is activated, the crimping body is disposed on the heating part. The heating part includes an inductive heating coil. The inductive heating coil surrounds in the heating part. The inductive heating coil is provided for heating the crimping body to soften the crimping body, in which the driving part is provided for driving the stamper part to press the soften crimping body, so that the connecting body and the to-be-joined member is crimped and to form a rigid crimping body after cooling. The present invention utilizes the coil with an alternative current to heat the crimping body by an electromagnetic induction, so that the process of the crimping technology is convenient and fast.