Overlapping Inductor Coils for Compact Transverse Flow Heating
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Solution Overview
Problem
Current transverse flow induction heating devices for steel products face limitations in power density and temperature profile adjustment, leading to inefficient heating and potential overheating, particularly in the steel industry where high power is required to achieve rolling temperatures efficiently.
Innovation Solution
The design involves an inductor with coils positioned to overlap partially on each side of the product, allowing for adjustable magnetic field control and power density distribution, along with a heating installation that includes adjustable coil positions and separate power sources for enhanced temperature homogeneity and reduced length requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple inductors are placed in series to increase power, then the required heating power is achieved, but the total length of the heating installation becomes very large
Solution Approach 1:
The patent combines multiple coils into a single inductor assembly where coils are disposed on both sides of the product with overlapping surfaces. This merging approach achieves the required heating power (up to 1.5 MW or more) within a compact length, eliminating the need for multiple series-connected inductors that would occupy 20 meters or more of space.
Solution Approach 2:
The patent transitions from a single-sided coil arrangement to a dual-sided configuration with coils on both sides of the product. The coils overlap in the transverse direction, creating a three-dimensional magnetic field distribution that increases power density without extending the longitudinal length of the installation.
2Device complexity
If conventional single-coil inductors are used, then the structure is simple, but the temperature profile adjustment range is limited and edge overheating cannot be fully controlled
Solution Approach 1:
The inductor is segmented into multiple coils (at least two per side) that can be independently controlled. Each coil can be adjusted individually to create different magnetic field distributions, enabling precise control of the temperature profile across the product width and preventing edge overheating while maintaining reasonable structural complexity.
Solution Approach 2:
Different regions of the product receive customized heating through locally adjusted coils. The coils on each side can be positioned at different distances from the product face, allowing selective concentration of heating power in specific zones (center or edges) according to the required temperature profile, thereby achieving local quality control.
3Productivity
If high power density is applied to heat the product quickly, then the heating efficiency is improved, but the temperature homogeneity deteriorates and edge overheating occurs
Solution Approach 1:
The inductor system provides dynamic control of the temperature profile through adjustable coil positions and independent coil control. The coils can be repositioned relative to the product face to optimize the magnetic field distribution, enabling the system to adapt to different heating requirements and maintain temperature homogeneity even at high power densities.
Solution Approach 2:
The patent changes the spatial parameters of the coil arrangement (distances from product face, overlapping configuration) to optimize the magnetic field distribution. By adjusting these parameters, the system achieves high power density while maintaining uniform temperature distribution across the product, preventing edge overheating.
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 configuration achieves higher power density and a broader temperature profile adjustment range, ensuring better temperature homogeneity and efficiency in heating steel products, addressing the limitations of existing systems.
Implementation Method 1
Device for heating a product by transverse flow induction
Implementation Method 2
induction heating means allow it to be brought to suitable conditions for rolling
Data Source
AI summary
An inductor intended to heat a flat product by transverse flow induction, with an upper face and a lower face, comprising coils having surfaces which extend over planes, are parallel to each other, and with a thickness in a direction perpendicular to the planes; and a central space between the coils. Wherein at least two coils are disposed on a first side of the central space and at least two coils are disposed on a second side of the central space, wherein on the same side of the central space, the coil closest to the face is spaced apart therefrom by a first distance and the other coils are disposed at a distance from the face that is at least equal to the first distance plus the thickness of the coils between them and the face of the product, and wherein the surfaces of the coils at least partially overlap.