Overlapping Inductor Coils for Compact High-Power Flat Product Heating
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Solution Overview
Problem
Existing transverse flux induction heating systems for flat products face limitations in power density and temperature profile adjustment, particularly in steelmaking applications, where high power density is required to achieve desired temperature increases within dimensional constraints, and current systems struggle to provide sufficient adjustment range for temperature homogeneity.
Innovation Solution
An inductor design with overlapping coils on either side of the product, adjustable positions, and multiple power sources to control magnetic field lines and power density, allowing for precise temperature control and enhanced power distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple inductors are connected in series to increase power output, then the total power output increases, but the total length of the heating system increases significantly
Solution Approach 1:
The patent combines multiple coils into a single integrated inductor assembly with overlapping coil structures. This merging approach allows the system to achieve high power output (equivalent to multiple series-connected inductors) while maintaining a compact form factor, thereby resolving the contradiction between power output and system length.
Solution Approach 2:
The patent employs a nested coil configuration where coils are arranged in overlapping layers with specific spacing relationships. The second coil is positioned at a distance from the product face that is at least equal to the thickness of the first coil plus its offset, creating a nested structure that maximizes power density within a limited spatial envelope, thus achieving high power output without proportionally increasing system length.
2Adaptability or versatility
If the heating system uses fixed coil positions, then the structure is simple, but the temperature profile adjustment range is limited
Solution Approach 1:
The patent introduces adjustable coil positioning mechanisms that allow the relative positions of coils to be modified during operation. This dynamic adjustment capability enables flexible temperature profile control by varying the magnetic field distribution, while the adjustment mechanisms are designed to be integrated into the existing inductor structure, minimizing additional complexity.
Solution Approach 2:
The patent utilizes adjustable parameters including coil-to-product distance, coil-to-coil spacing, and coil overlap程度 to control the temperature profile. By changing these geometric parameters, the system can achieve a wide range of temperature distributions across the product surface, enhancing adaptability without requiring fundamentally different heating mechanisms.
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 solution provides high power density and a broader range of temperature profile adjustment, ensuring better temperature homogeneity and efficiency in heating processes.
Implementation Method 1
Device for heating a product by transverse flux induction
Implementation Method 2
induction heating systems bring it to the appropriate rolling conditions
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
An inductor (20) intended to heat a flat product (1) by transverse flow induction, said product having an upper face (1fs) and a lower face (1fi), said inductor comprising coils (2as, 2ai, 2bs, 2bi) having surfaces (S2as, S2ai, S2bs, S2bi) extending over planes (P2as, P2ai, P2bs, P2bi) that are substantially parallel to each other, and a thickness (Eas, Eai, Ebs, Ebi) in a direction perpendicular to these planes, the inductor also comprising a central space (3) between the coils that is intended to receive the product (1), wherein at least two coils (2as, 2ai) are disposed on a first side of the central space (3) and at least two coils (2bs, 2bi) are disposed on a second side of the central space (3) opposite the first, wherein, on the same side of the central space (3), the coil (2ai, 2bi) closest to the face (1fs, 1fi) of the product is spaced apart therefrom by a first distance (Dai, Dbi) and the other coils are disposed at a distance from the face of the product that is at least equal to the first distance (Dai, Dbi) plus the thickness (Eai, Ebi) of the coils disposed between them and the face of the product, and in that the surfaces (P2as, P2ai, P2bs, P2bi) of the coils at least partially overlap.