Inductive Pipe End Heating with Adjustable Flux Diverter
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Solution Overview
Problem
Existing pipe end heating technologies are limited in their ability to vary heated lengths and diameters without requiring multiple coil setups or adjustments, leading to inefficiencies and increased costs in the oil country tubulars production process.
Innovation Solution
A flexible pipe end heating apparatus featuring a solenoid coil with distributed turns and an adjustable flux diverter, allowing for universal applicability across various diameters and heated lengths without the need for coil changes or tapping, utilizing a pulse width modulated AC power supply for efficient inductive heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed solenoid coil is used for pipe end heating, then the heating process is simple, but the heated length cannot be varied without changing the coil
Solution Approach 1:
The patent applies the dynamics principle by making the coil configuration adjustable rather than fixed. The coil can be repositioned along the pipe length, and the number of active turns can be varied, allowing the heated length to be dynamically changed without replacing the entire coil assembly. This resolves the contradiction by enabling adaptability while maintaining a single coil structure.
Solution Approach 2:
The coil is divided into multiple independent sections or turns that can be selectively activated. By controlling which segments of the coil are energized, the heated length can be precisely adjusted. This segmentation allows the system to achieve variable heated lengths without requiring multiple complete coils, thus improving adaptability without proportionally increasing device complexity.
2Manufacturing precision
If multiple coils are supplied for different heated lengths, then each heated length can be precisely achieved, but the cost and productivity are negatively impacted
Solution Approach 1:
The patent implements a universal coil design that can perform multiple functions by adjusting the number of active turns and coil position. A single coil assembly can heat various lengths of pipe by simply reconfiguring which turns are energized, eliminating the need for multiple specialized coils. This multi-functionality maintains manufacturing precision while dramatically improving productivity by removing coil change operations.
Solution Approach 2:
The system dynamically reconfigures the active coil segments to match the required heated length. Rather than physically changing coils, the system adjusts which portions of the coil are energized, allowing rapid transition between different heated lengths. This dynamic reconfiguration maintains precision heating control while eliminating the time-consuming coil replacement process.
3Adaptability or versatility
If coil taps are used to adjust heated length, then some flexibility is achieved, but substantial production loss occurs due to tapping changes
Solution Approach 1:
The coil is pre-configured with multiple accessible taps or connection points along its length, allowing rapid selection of different heated lengths without physical reconfiguration. The preliminary arrangement of taps enables operators to quickly connect to the desired section, minimizing adjustment time. This preliminary preparation achieves adaptability while reducing the time penalty associated with changes.
Solution Approach 2:
The system enables dynamic selection of active coil segments through easily accessible taps or electrical switching. Rather than requiring physical coil reconfiguration, the operator can quickly change the active heating section by selecting different taps, achieving rapid adaptation with minimal production interruption.
4Adaptability or versatility
If a universal heating apparatus is designed for various diameters and lengths, then flexibility is improved, but the device complexity increases
Solution Approach 1:
The apparatus incorporates adjustable coil positioning mechanisms and variable turn activation that allow the same coil to accommodate different pipe diameters and heated lengths. By making the coil configuration dynamic rather than fixed, the system achieves universality without requiring multiple specialized coils or complex interchangeable assemblies. The adjustable nature of the system provides flexibility while maintaining a relatively simple 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
Enables uniform and controlled heating of pipe ends across a wide range of diameters and lengths, enhancing productivity and reducing setup time and costs by allowing a single system to accommodate multiple pipe sizes and configurations.
Implementation Method 1
A flexible pipe end heating apparatus featuring a solenoid coil with distributed turns and an adjustable flux diverter, allowing for universal applicability across various diameters and heated lengths without the need for coil changes or tapping, utilizing a pulse width modulated AC power supply for efficient inductive heating.
Implementation Method 2
efficient inductive heating
Implementation Method 3
positioning a flux diverter along the axis with a diverter structure end facing the pipe end to divert flux from the coil to control inductive heating of the pipe end
Data Source
AI summary
Induction heating apparatus and methods are presented for pipe end heating using a solenoid coil to heat a controlled length of a pipe workpiece by adjusting the relative positions of the solenoid coil with a flux diverter positioned relative to the pipe end to divert flux from the coil to control inductive heating of the pipe workpiece end.