Modular Induction Heating Cells for Non-Planar Surfaces
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Solution Overview
Problem
Conventional induction heating systems are inefficient for heating parts with non-planar surfaces due to the mismatch between the shape of the electrically conducting object and the surface of the part to be heated.
Innovation Solution
An array of induction heating cells that are movable and couplable via hinges, wires, or other features to conform to non-planar surfaces, with each cell being individually controllable for temperature, frequency, and power, and a feedback system to adjust these parameters for efficient heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single electrically conducting object is used for induction heating, then the structure is simple and easy to manufacture, but it cannot conform to non-planar surfaces resulting in heating inefficiency
Solution Approach 1:
The electrically conducting object is divided into multiple electrically conducting segments that can be independently positioned and shaped. Each segment can conform to different portions of a non-planar surface, allowing the overall structure to adapt to complex geometries while maintaining manufacturing simplicity for each individual segment.
Solution Approach 2:
The electrically conducting segments are made movable relative to one another, allowing dynamic adjustment of the array configuration. This enables the heating array to adapt its shape to match non-planar surfaces of workpieces, improving heating efficiency without requiring a completely new rigid structure.
2Productivity
If the electrically conducting object is shaped to match a planar surface, then heating efficiency is improved for planar surfaces, but it becomes ineffective for non-planar surfaces
Solution Approach 1:
By segmenting the electrically conducting object into multiple independent units, each segment can be individually positioned to match different surface geometries. This segmentation enables the array to maintain high heating efficiency across both planar and non-planar surfaces through flexible configuration.
Solution Approach 2:
The array of electrically conducting segments is designed to perform multiple functions: it can effectively heat both planar and non-planar surfaces, and can be configured for different workpiece geometries. This universal applicability eliminates the limitation of being optimized for only one surface type.
3Adaptability or versatility
If multiple induction heating cells are used to cover non-planar surfaces, then adaptability to surface shape is improved, but device complexity increases
Solution Approach 1:
The system is segmented into multiple independent electrically conducting segments that can be individually controlled. This segmentation allows complex surface adaptation to be achieved through simple, repeatable modular units rather than a single complex structure.
Solution Approach 2:
The control system receives feedback regarding the position and orientation of each electrically conducting segment and automatically adjusts their configuration to match the workpiece surface geometry. This feedback mechanism automates the adaptation process, reducing the operational complexity despite the multi-component system.
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 efficient induction heating of non-planar surfaces by allowing the induction heating cells to adapt to the shape of the part, providing precise control over heating parameters for effective curing or heat treatment.
Implementation Method 1
Induction heating uses an electrically conducting object to heat a part using electromagnetic induction through heat generated in the electrically conducting object by eddy currents
Implementation Method 2
heat generated in the electrically conducting object by eddy currents
Data Source
AI summary
Described herein is an apparatus for induction heating. The apparatus includes a plurality of induction heating cells attachably coupled together. Each induction heating cell of the plurality of induction heating cells is movable relative to adjacent induction heating cells of the plurality of induction heating cells to conform the plurality of induction heating cells to a non-planar surface. Each induction heating cell of the plurality of induction heating cells includes a power connector and a coupling feature to couple the respective induction heating cell with one or more other induction heating cells of the plurality of induction heating cells.