Mobile Inductor Assembly for Vibration-Free Hardening
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Solution Overview
Problem
Conventional hardening systems face limitations in achieving high-quality hardening, especially for pieces with cylindrical symmetry far from the center of mass, due to vibration-induced low rotation speeds and power density issues, which restrict the ability to perform hardening effectively without complex machinery and precise control.
Innovation Solution
An induction heating system with a mobile secondary winding and heating inductor assembly, powered by an output transformer with a transmission axis, allowing for linear and angular movement without physical contact between primary and secondary windings, enabling independent hardening of pieces with cylindrical symmetry by maintaining constant current density and reducing leakage inductance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the piece rotates about an axis far from the centre of mass to achieve hardening with cylindrical symmetry, then the hardening quality is improved, but heavy vibrations occur and rotation speeds are limited
Solution Approach 1:
Instead of rotating the piece about an axis far from its center of mass (which causes vibrations), the patent inverts the approach by rotating the inductor assembly while keeping the piece stationary or rotating about its own center of mass. The mobile secondary winding and inductor rotate around the piece, achieving cylindrical symmetry hardening without subjecting the piece to harmful vibrations.
Solution Approach 2:
The patent introduces a mobile secondary winding coupled with the inductor as an intermediary system. This assembly can rotate independently around the piece, mediating the energy transfer process. The mobile secondary winding is coupled to the inductor and can rotate around the piece, allowing the inductor to follow the piece's contour without directly rotating the piece itself, thus avoiding vibration issues.
2Object-affected harmful factors
If low rotation speeds are used to avoid vibrations, then vibrations are reduced, but power density in the inductor decreases and cycle time increases
Solution Approach 1:
The patent inverts the traditional approach by making the inductor mobile rather than the piece. The mobile secondary winding and inductor assembly rotates around the stationary or slowly rotating piece, enabling high rotation speeds of the inductor without inducing vibrations in the piece. This inversion allows high power density while avoiding harmful vibrations.
Solution Approach 2:
The patent introduces dynamic capabilities to the inductor system through the mobile secondary winding that can rotate and adjust its position. This dynamic inductor assembly can optimize its rotational speed independently of the piece's rotation, maintaining high power density while avoiding vibration-induced speed limitations.
3Device complexity
If the inductor remains static while the piece rotates, then the system is simpler, but adequate hardening cannot be achieved for pieces with strict requirements and large sizes
Solution Approach 1:
The patent transforms the static inductor into a dynamic system with a mobile secondary winding that can rotate and move relative to the piece. This dynamic capability allows the inductor to follow the piece's contour and maintain optimal positioning, achieving adequate hardening for large pieces with strict requirements while managing system complexity through controlled mobility.
Solution Approach 2:
The mobile secondary winding and inductor assembly serves multiple functions: it can rotate around the piece, adjust its position to follow the piece's contour, and maintain consistent energy transfer. This multi-functional design allows a single system to handle various piece sizes and hardening requirements that would otherwise require different specialized systems.
4Volume of moving object
If large machines and large motors are used to rotate large pieces, then large pieces can be hardened, but the machine size and motor size increase significantly
Solution Approach 1:
The patent inverts the traditional hardening configuration by keeping the piece stationary or rotating slowly about its own axis, while the inductor assembly rotates around the piece. This inversion eliminates the need for large motors to rotate large pieces, as the inductor's rotation is driven by a smaller mobile secondary winding system that can accommodate various piece sizes without proportionally increasing machine size.
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 system enhances hardening quality by allowing greater rotation speeds and power transfer, enabling efficient hardening of pieces with cylindrical symmetry without the need for complex machinery or precise piece rotation, thereby improving cycle times and power density.
Implementation Method 1
an output transformer which is able to transfer the necessary energy for hardening without there being any physical union between the primary and the secondary winding of said transformer
Implementation Method 2
an inductor which will be responsible for transferring the energy that the piece needs for hardening
Implementation Method 3
hardening or induction heating system
Data Source
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AI summary
The invention consists in the development of tempering systems which have a cylindrical symmetry without the piece to be tempered having to perform any movement. The system is capable of performing a rotational movement of the assembly formed by the secondary winding of the output transformer (5) and the inductor (3) about its longitudinal axis of symmetry and a displacement along the same axis. This movement is performed while the energy necessary for tempering a piece by means of induction is being transferred. Energy transfer is performed without the presence of mechanical contacts by means of a magnetic field, i.e. is performed by means of physical separation between the primary winding (4) and the secondary winding of the output transformer (5) with a rotating movement.