Modular Transformer Couplers for Induction Heating Impedance Matching
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Solution Overview
Problem
Conventional induction heating systems require direct manipulation of exposed transformer windings to adjust the ratio of primary to secondary windings for impedance matching, which is inefficient and cumbersome.
Innovation Solution
A modular transformer system with hermetically sealed windings allows for interchangeable couplers with different winding configurations, enabling adjustment of the primary to secondary winding ratio without direct access to exposed wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional transformer windings are used with direct manipulation, then impedance matching can be achieved, but the operation becomes inefficient and cumbersome
Solution Approach 1:
The transformer is divided into separate modular components: a primary winding assembly and a secondary winding assembly that can be independently manufactured and then coupled together. This segmentation allows each module to be pre-configured with specific winding ratios, enabling quick interchange to achieve different impedance matching requirements without time-consuming manual adjustments to exposed windings.
Solution Approach 2:
The system enables dynamic reconfiguration of the transformer by allowing operators to swap out coupling assemblies with different winding ratios based on the specific impedance matching requirements. This dynamic adaptability eliminates the need for manual manipulation of exposed windings, significantly reducing adjustment time while maintaining operational flexibility.
2Adaptability or versatility
If exposed transformer windings are used for adjustment, then winding ratio can be changed, but safety risks increase due to direct manipulation of exposed wires
Solution Approach 1:
The transformer windings are segmented into isolated modular assemblies with all electrical connections enclosed within each module. This segmentation allows the winding ratio to be changed by swapping entire sealed assemblies rather than manipulating exposed wires, maintaining adaptability while eliminating safety hazards from exposed electrical components.
Solution Approach 2:
Coupling assemblies serve as intermediaries between the primary and secondary windings, providing a sealed interface that allows winding ratio changes without exposing electrical connections. These coupling assemblies act as protective mediators that enable configuration changes while preventing direct contact with hazardous exposed wires.
3Ease of operation
If modular couplers with hermetically sealed windings are used, then safety and flexibility are improved, but device complexity increases
Solution Approach 1:
While segmentation into modular components does increase the number of parts, it simplifies the overall system architecture by creating standardized, self-contained units. Each coupling assembly is a complete, pre-configured module that requires no field assembly or complex wiring, making the system easier to install, maintain, and reconfigure despite the modular structure.
Solution Approach 2:
The coupling assemblies are designed with universal interfaces and standardized connection mechanisms that can be used across different transformer configurations. This universality reduces the need for custom components and simplifies the system overall, as the same basic coupling design can accommodate various winding ratios and configurations through interchangeable modules rather than requiring unique solutions for each scenario.
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
Facilitates efficient impedance matching and voltage adjustment by allowing operators to swap couplers with different winding configurations, enhancing flexibility and safety by eliminating the need for direct manipulation of exposed wires.
Implementation Method 1
a first power coupler and a second power coupler configured to magnetically couple to form a transformer through which induction heating power is transferred
Implementation Method 2
The varying current in the loop creates a varying magnetic flux within the metal to be heated. Current is induced in the metal by the magnetic flux and the internal resistance of the metal causes it to heat up
Implementation Method 3
Current is induced in the metal by the magnetic flux and the internal resistance of the metal causes it to heat up
Data Source
Figure 1
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AI summary
Apparatuses, systems, and/or methods for an induction heating system are disclosed. In some examples, the induction heating system includes an induction heating power supply and an induction heating tool configured to receive induction heating type power from the induction power supply through a modular transformer. In some examples, the modular transformer comprises a first coupler (e.g., a power receptacle) and a second coupler (e.g., a power insert) configured to couple together to complete the modular transformer, and/or decouple to separate the modular transformer. In some examples, the first coupler is in electrical communication with the induction heating power supply, and the second coupler is in electrical communication with the induction heating tool. When the first and second couplers are coupled together to complete the modular transformer, induction heating power flows through the modular transformer from the induction heating power supply to the induction heating tool.