Rotatable Carrier Induction Heating for Uniform Metal Hardening
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Solution Overview
Problem
Current induction heating technologies are inefficient in uniformly heating and hardening multiple small metal objects simultaneously while minimizing energy consumption and ensuring quick quenching processes.
Innovation Solution
An induction heating apparatus with a rotatable carrier system that positions metal objects in a circular array for uniform heating by a single large coil, utilizing actuators and a controller to guide and rotate the carrier for precise positioning and rapid ejection into a quench bath.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple small metal objects are heated individually using conventional induction heating technologies, then each object can be heated, but the energy consumption increases and the processing time extends significantly
Solution Approach 1:
Multiple small metal objects are arranged simultaneously on a rotatable carrier within a single large induction coil, allowing simultaneous heating of multiple parts in one location. This merging approach consolidates what would otherwise require multiple separate heating zones or coils, significantly improving productivity while reducing overall energy consumption compared to individual heating processes
Solution Approach 2:
The patent transitions from heating parts in a linear sequence to arranging them in a two-dimensional circular array on the rotatable carrier. This dimensional change allows a single large coil to effectively heat multiple parts simultaneously by rotating the carrier through the coil's magnetic field, achieving both high productivity and energy efficiency
2Loss of energy
If a single large induction coil is used to heat multiple parts simultaneously, then energy efficiency improves, but the positioning precision and uniformity of heating across all parts becomes difficult to achieve
Solution Approach 1:
The carrier is designed to rotate dynamically within the induction coil during the heating process. This rotation ensures that all parts positioned on the carrier receive uniform exposure to the coil's magnetic field, achieving consistent heating across all parts while maintaining energy efficiency. The dynamic motion compensates for the single large coil's inability to provide focused localized heating
Solution Approach 2:
While using a single large coil for overall energy efficiency, the system achieves local quality control through selective part placement on the rotatable carrier. Parts can be positioned in specific locations and orientations on the carrier to optimize their exposure to the magnetic field, ensuring uniform heating characteristics for each part type while maintaining the energy benefits of a single coil
3Productivity
If parts are heated in a batch process, then productivity increases, but the quenching speed and hardness uniformity may be compromised
Solution Approach 1:
All parts are simultaneously heated to the required temperature while positioned on the rotatable carrier before the quenching operation begins. This preliminary batch heating ensures uniform temperature distribution across all parts, and then the entire carrier can be rapidly transferred to the quenching medium, achieving both high productivity and fast quenching speed without compromising hardness uniformity
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
Enables simultaneous and uniform heating of multiple metal objects with reduced energy consumption and faster quenching times compared to conventional systems, allowing for efficient hardening of dozens of parts per cycle.
Implementation Method 1
induction heating device... induction heat the rotating at least one metal object
Implementation Method 2
The apparatus includes an induction heating device disposed adjacent to the rails
Implementation Method 3
The heated part is then ejected from the apparatus and directly into a quench bath
Data Source
AI summary
An apparatus includes rails for supporting sides of a circumferential peripheral edge of a carrier. A movable ram engages a rearward portion of the carrier. A movable restrainer restrains movement of the ram. A wheel engages a forward portion of the carrier. A controller is operable to control the movable restrainer to restrain movement of the ram with the carrier and at least one metal object disposed adjacent an induction heating device, the wheel to rotate the carrier and the metal object, the induction heating device to induction heat the rotating metal object, and the movable restrainer to disengage the ram so that the wheel pivots away to allow passage of the carrier and the heated metal object into a quench bath. A plurality of metal objects may be arranged in a circular array in the carrier about a diameter generally equal to the diameter of an induction coil.