Ring Rolling Inductor Tracking for Stable Workpiece Heating
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Solution Overview
Problem
Existing methods for inductive heating of ring-shaped rolling products during the rolling process are cumbersome and costly due to the need for enclosing the workpiece with a magnetizable core, which is not efficient in compensating for increasing heat losses as the product size grows.
Innovation Solution
A method using an inductor held at a constant coupling distance relative to the rolling product, tracking its changes in dimensions, and inducing an alternating magnetic field between 4 and 10 kHz to heat the product without the need for an electrically conductive core, with the inductor positioned on the outer circumference and adjusted using sensors or spacers to maintain optimal distance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a closed or C-shaped magnetizable core is used to enclose the workpiece for inductive heating, then the workpiece can be heated during the rolling process, but the device becomes cumbersome and costly
Solution Approach 1:
The patent extracts the magnetizable core from the heating system, eliminating the need for enclosing the workpiece. Instead, a simple inductor generates an alternating magnetic field that directly induces eddy currents in the workpiece, achieving heating without the complex core structure.
Solution Approach 2:
The patent introduces an alternating magnetic field as an intermediary between the power source and the workpiece. The inductor generates this magnetic field, which penetrates the workpiece and induces eddy currents, serving as a non-contact energy transfer medium that eliminates the need for physical enclosures.
2Volume of moving object
If the rolling product diameter increases during rolling, then the surface area increases, but heat losses through radiation increase accordingly
Solution Approach 1:
The patent applies continuous inductive heating throughout the rolling process. The inductor follows the workpiece along its rolling path, ensuring continuous energy input that compensates for ongoing radiative heat losses as the workpiece surface area increases during deformation.
Solution Approach 2:
The patent performs preliminary heating before and during the early stages of rolling to establish a high initial temperature. This preliminary action creates a temperature reserve that compensates for increasing heat losses as the workpiece grows in size during the rolling process.
3Power
If an inductor is positioned close to the rolling product for effective heating, then heating efficiency improves, but the inductor must be precisely positioned and tracked during the rolling process
Solution Approach 1:
The patent employs a dynamic positioning system where the inductor is mounted on a movable support structure that can follow the workpiece during rolling. This dynamic adjustment maintains the optimal coupling distance between the inductor and workpiece surface, ensuring consistent heating efficiency as the workpiece dimensions change.
Solution Approach 2:
The patent implements a feedback control system that monitors the distance between the inductor and the workpiece surface. Based on this feedback, the system automatically adjusts the inductor position to maintain optimal coupling, ensuring efficient heating while simplifying operation through automated control.
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 method effectively compensates for temperature losses with minimal effort by maintaining a consistent heating process as the rolling product changes dimensions, reducing the need for costly enclosures and enhancing efficiency in temperature control.
Implementation Method 1
an alternating magnetic field, preferably with a frequency between 4 and 10 kHz, is directly coupled into the rolling product by the inductor
Implementation Method 2
inductive heating of the rolling product during the rolling process
Implementation Method 3
inducing an alternating magnetic field in the rolling product and consequent heating of the rolling product
Data Source
AI summary
A method for rolling a ring-shaped rolling product (5) having an open cylindrical cross section in a ring rolling machine (1) with inductive heating of the rolling product (5) during the rolling process uses at least one inductor (12) which is held at a predefined coupling distance relative to the rolling product (5) and is tracked or carried along during the shaping process in accordance with the change in dimensions of the rolling product (5). An alternating magnetic field, preferably with a frequency of between 4 and 10 kHz, is coupled directly into the rolling product (5) using the inductor (12).