Integrated Frequency Converter for Precise Induction Adhesive Curing
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Solution Overview
Problem
Existing induction systems for adhesive curing in the automotive sector face challenges such as lengthy curing times, mechanical distortion due to non-selective heating, high energy consumption, and limited control over temperature at adhesive points, leading to inefficiencies and increased costs.
Innovation Solution
The induction system features intelligent induction units with integrated frequency converters, bidirectional communication interfaces, and decentralized power electronics, allowing for individual control of heating power and temperature at each adhesive point, along with a flexible cabling system and sequence control for coordinated heating processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If induction points are connected in series with a single power source, then the system structure is simplified, but ideal temperature control at all adhesive points becomes impossible
Solution Approach 1:
The patent divides the induction system into independent parallel-connected induction points, each with its own power source. This segmentation allows each adhesive point to be controlled independently, achieving ideal temperature control at all points simultaneously while maintaining a relatively simple system structure through modular design.
2Productivity
If high inductive heating power is provided at endpoint, then adhesive curing is effective, but mechanical distortion and high energy consumption occur
Solution Approach 1:
The patent applies local quality by providing inductive heating power selectively at specific adhesive points rather than uniformly across the entire workpiece. Each induction point delivers high power locally where needed for effective adhesive curing, while other areas remain unaffected, thus preventing mechanical distortion and reducing overall energy consumption.
3Reliability
If entire workpiece is heated in continuous oven, then adhesive curing is achieved, but lengthy curing time and high energy consumption result
Solution Approach 1:
The patent extracts the heating function from a continuous oven that heats the entire workpiece and implements it at specific adhesive points only. This extraction of the heating function to localized induction points enables rapid curing at each bond location without the time and energy penalties of heating the entire workpiece in a continuous oven.
4Ease of manufacture
If induction units are grouped and connected in series, then wiring effort is reduced, but heating output of all induction units can only be controlled jointly
Solution Approach 1:
The patent segments the induction units into independent parallel-connected groups, where each group can be controlled independently. This segmentation provides heating control flexibility for different workpiece zones while reducing wiring effort through modular group connections, allowing adaptability to various heating requirements without excessive wiring complexity.
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 solution enables precise temperature control at each adhesive point, reduces mechanical distortion, and minimizes energy consumption, resulting in improved process efficiency and cost-effectiveness by allowing for real-time monitoring and adjustment of heating processes.
Implementation Method 1
an induction unit (10), in particular a spot induction unit, with an induction coil whose heating power can be regulated
Implementation Method 2
induction bonding systems are produced for this purpose that map the respective component geometry
Implementation Method 3
an integrated frequency converter, whereby the heating output of an induction coil can be controlled and regulated individually and independently
Data Source
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AI summary
An induction system and a method for operating an induction system are proposed, wherein the power electronics, which according to the prior art are centrally installed in a large control cabinet, are reduced in size and price to such an extent that they can be housed directly on the induction unit(s), resulting in at least one intelligent induction unit with integrated frequency converter, which is preferably supplied with normal mains current of 230 V or 400 V or with direct current.