Offset Induction Coil for Thin Metal Plate Heating
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Solution Overview
Problem
Conventional induction heating systems face challenges in efficiently heating thin, nonmagnetic metal plates and maintaining uniform temperature distribution, particularly due to issues with current penetration depth and magnetic properties, leading to overheating and temperature deviations.
Innovation Solution
The induction heating system employs an induction coil with conductors arranged on both surfaces of the metal plate, offset in the longitudinal direction to prevent interference, and includes slanted conductors and magnetic cores to manage flux and current distribution, allowing for precise temperature control and efficient heating of both magnetic and nonmagnetic materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If LF system induction heating is used, then temperature distribution uniformity is improved, but thin nonmagnetic plates cannot be heated effectively due to deep current penetration depth
Solution Approach 1:
The induction coil is divided into multiple sections along the longitudinal direction, with each section having conductors offset from the plate center. This segmentation allows the magnetic flux to be distributed across multiple zones, creating overlapping induction current paths that effectively heat thin nonmagnetic plates while maintaining uniform temperature distribution.
Solution Approach 2:
The conductors are arranged offset from the plate center in the longitudinal direction, moving the flux generation from a central symmetric position to asymmetric positions along the length of the plate. This dimensional shift creates a flux distribution pattern that penetrates the entire plate thickness uniformly, solving the penetration depth issue for thin nonmagnetic materials.
2Reliability
If TF system induction heating is used, then heating capability for thin and nonmagnetic plates is improved, but uneven temperature distribution occurs and magnetic materials are drawn to inductors
Solution Approach 1:
The conductors are positioned asymmetrically offset from the plate center rather than being centered. This asymmetric arrangement creates a magnetic flux pattern that passes through the plate in a way that generates uniform induction currents across the entire plate surface, preventing the concentration of flux at specific locations that causes uneven heating and material attraction in conventional TF systems.
Solution Approach 2:
The flux generation is shifted from the plate center to offset positions along the longitudinal direction. This dimensional change in flux path creates overlapping magnetic field zones that uniformly penetrate the plate, achieving both effective heating of thin nonmagnetic plates and uniform temperature distribution simultaneously.
3Device complexity
If conventional induction coil arrangement is used, then simple structure is maintained, but temperature deviations occur at plate ends and center
Solution Approach 1:
The induction coil is segmented into multiple sections along the longitudinal direction, with each section contributing to heating a specific zone. The offset conductor arrangement in each section creates overlapping heating zones that compensate for edge effects and center temperature deviations, achieving uniform temperature distribution across the entire plate including ends and center.
Solution Approach 2:
Different sections of the induction coil are positioned to address specific thermal zones of the plate. The offset conductor arrangement creates localized flux patterns that can be optimized for different plate regions, with the cumulative effect of multiple sections providing uniform temperature distribution across the entire plate surface.
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 approach enables effective heating of thin, nonmagnetic materials and reduces temperature deviations, allowing for stable high-quality production with flexible heating rates and reduced capital costs, as it can handle changes in plate thickness and width without compromising productivity.
Implementation Method 1
running a primary current 5 through it whereby a flux 4 runs through the inside of the metal plate 1, an induction current is generated around the flux 4, and the generated induction current heats the metal plate 1
Implementation Method 2
an induction current is generated around the flux 4, and the generated induction current heats the metal plate 1
Implementation Method 3
said front surface side conductor and back surface side conductor being arranged having a distance apart so as not to mutually overlap each other in a longitudinal direction of said metal plate at the center part
Implementation Method 4
at least either of said front surface side and back surface side conductors of each of said at least two sections of the induction coil having a part slanted with respect to the width direction toward at least either of the ends of the metal plate in the width direction
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A system for induction heating a metal plate passing through an inside of an induction coil, which induction heating system arranging at least two sections of the induction coil adjacent in a longitudinal direction of said metal plate, wherein when vertically projecting the induction coil of the front surface side and back surface side of said metal plate onto said metal plate, said front surface side and back surface side conductors are arranged offset so as not to overlap in the longitudinal direction of said metal plate in that vertical projection, further, said front surface side conductors being in proximity and said back surface side conductors being arranged having a distance apart more or said back surface side conductors being in proximity and said front surface side conductors being arranged having a distance apart more, said induction heating system able to control the heating temperature distribution even for thin metal plate without regard to being magnetic or nonmagnetic, in particular an induction heating system able to control the temperature at the ends of the metal plate, and an induction heating method for the same.