Planar Inductor Ceramic Spacing Elements Gap Control
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Solution Overview
Problem
Existing planar inductors for progressive surface layer hardening face challenges in maintaining a consistent spacing gap between the induction coil and the workpiece, leading to potential direct contact and damage due to attraction forces during the hardening process, especially when using a measuring roller for gap measurement.
Innovation Solution
Incorporating two spaced-apart ceramic spacing elements into the carrier to maintain a minimum gap and prevent direct contact between the induction coil and the workpiece, ensuring stable support and avoiding interference with the inductor's function, while allowing for adjustable gap tracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a small spacing gap is set between the induction coil and the workpiece surface, then heating efficiency is improved, but direct contact and local overheating may occur
Solution Approach 1:
A plastics strip made from polytetrafluoroethylene is introduced as an intermediary spacer between the induction coil and the workpiece surface. This mediator maintains the necessary spacing to prevent direct contact and damage while allowing the coil to operate at optimal proximity for efficient heating.
Solution Approach 2:
The plastics strip is positioned in advance before the hardening operation begins. This preliminary action ensures that the spacing gap is established before significant attraction forces develop, preventing direct contact from the outset while enabling immediate heating efficiency.
2Measurement precision
If a measuring roller is used to maintain distance, then gap measurement is improved, but the system cannot handle attraction forces at the beginning of hardening
Solution Approach 1:
The plastics strip serves as a mechanical intermediary that can withstand attraction forces directly, unlike the measuring roller which only measures distance. The strip physically supports the coil against the workpiece surface during high-force conditions.
Solution Approach 2:
The plastics strip is designed as a consumable component that can be easily replaced. It sacrifices itself to prevent damage to more critical components, serving its protective function until it wears or degrades, at which point it is replaced rather than repaired.
3Object-affected harmful factors
If the plastics strip remains too long between the inductor and surface, then contact prevention is maintained, but the strip may melt or disintegrate causing soiling
Solution Approach 1:
The system monitors the condition and position of the plastics strip, and automatically triggers its removal or replacement when it approaches the end of its service life or when it no longer maintains the proper spacing. This self-service approach prevents degradation-related contamination.
Solution Approach 2:
A feedback mechanism tracks the duration and effectiveness of the plastics strip's performance. When the strip begins to degrade or fail to maintain proper spacing, the system receives feedback and automatically removes or replaces the strip before it can melt or disintegrate and cause soiling.
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 use of ceramic spacing elements ensures reliable operational separation and prevents damage by maintaining a consistent gap, enhancing the operational reliability and safety of the planar inductor during surface layer hardening.
Implementation Method 1
The conductor loop is located here in a plane which is parallel to the surface to be hardened, wherein a predetermined spacing gap remains between the conductor loop as the induction coil and the surface. In order to permit as efficient heating up by means of induction as possible
Implementation Method 2
The inductor, the surface arranged therebelow is heated to a temperature which causes a structural conversion of the surface layer
Data Source
AI summary
The present invention relates to a planar inductor for progressive case hardening, comprising a carrier and an induction coil, which is accommodated by the carrier and exposed on a first side of the carrier and which is in the form of a conductor loop. According to the invention, the inductor comprises two spacing elements, which are space apart from one another and inserted into the carrier and which protrude from the carrier and beyond the conductor loop on the first side. The invention further relates to a preferred method for producing the planar inductor.