Opposed Current Flow Magnetic Pulse Forming System
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Solution Overview
Problem
Magnetic pulse forming and joining technologies face limitations due to high inductance in conductor systems, which reduces the magnitude and rise time of the electromagnetic pulse force, and are not designed to minimize inductance, leading to inefficiencies and premature wear in closed coil configurations.
Innovation Solution
An opposed current flow magnetic pulse forming and joining system with multiple sections and conductors that minimize inductance by configuring each section as a separate electrical circuit, allowing current to flow in opposite directions through each conductor pair, reducing inductive reactance and impedance, and directing current flow to the working faces to maximize electromagnetic force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a closed coil configuration is used for magnetic pulse forming and joining, then the electromagnetic pulse force can be generated, but the workpiece geometry is limited to simple shapes and the coil suffers from premature wear due to sparking at interfaces
Solution Approach 1:
The coil is divided into multiple segmented sections that can be independently positioned and configured. Each section has conductive contacts that mate with corresponding sections, allowing the coil to be opened and closed around complex workpiece geometries without requiring the entire coil to be a single rigid structure. This segmentation enables adaptability to various workpiece shapes while maintaining reliable electrical connections through the conductive contact interfaces.
2Force
If traditional conductor systems are used in magnetic pulse technology, then the system can operate, but high inductance reduces the magnitude and increases the rise time of the electromagnetic pulse force
Solution Approach 1:
The conductor system is segmented into multiple sections with independent electrical circuits. Each section has its own conductors that are routed to minimize loop area and inductance. The conductors in each section are arranged in an opposed current flow configuration where current flows in opposite directions through adjacent conductors, creating magnetic fields that reinforce each other while canceling out inductive reactance. This segmentation allows optimization of each conductor path to minimize inductance while maintaining the required electromagnetic pulse force.
Solution Approach 2:
The conductor arrangement uses opposed current flow where current flows in opposite directions through adjacent conductors. This inversion of the conventional single-direction current flow creates a configuration where the magnetic fields from adjacent conductors add constructively at the workpiece location while the inductive reactance effects cancel each other out, reducing overall inductance and energy losses.
3Speed
If high inductance is present in the magnetic pulse system, then the system can operate with standard conductors, but the current frequency is reduced and the rise time of the magnetic pulse force increases
Solution Approach 1:
The electrical circuit is divided into multiple independent segmented sections, each with optimized conductor routing. By segmenting the system, the inductance of each individual section is reduced, allowing higher current frequencies to be achieved. The reduced inductance in each section enables faster current rise times, which directly translates to reduced rise time of the magnetic pulse force while maintaining high current frequency operation.
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
The system achieves improved quality and reliability in magnetic pulse forming and joining with reduced losses due to inductance, increasing the electromagnetic pulse force and reducing rise time without altering the power supply, and extends the system's life by minimizing inductance in conductors.
Implementation Method 1
magnetic pulse technologies, namely magnetic pulse forming and magnetic pulse joining, including welding... electromagnetic pulse force... current flowing through the sections
Data Source
AI summary
An opposed current flow magnetic pulse forming and joining system in electrical communication with a magnetic pulse power supply having a positive connection and a negative connection. The system may be used in forming individual workpieces or joining multiple workpieces, including joining by magnetic pulse welding. The system includes a first section, a second section, an insulator, and a first and a second pair of conductors. The first and second sections cooperate to enclose the workpiece(s) and function to create an electromagnetic force similar to that produced by a single closed coil. The system is configured to achieve desirable current flow by minimizing inductance, inductive reactance, and impedance in the conductors. The pairs of conductors may incorporate closely spaced individual conductors, braided conductors, and coaxial conductors. The current flow in the individual conductors of each pair of conductors is opposed, as is the current flow through the sections.