Rotating Magnetic Tool for Flexible Induction Hardening
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Solution Overview
Problem
Conventional magnetic induction hardening processes require dedicated and costly tooling for each part, with high electricity consumption and inflexibility due to the specific geometry and frequency requirements of inductors, limiting their applicability and efficiency.
Innovation Solution
A magnetic induction hardening apparatus with a magnetic tool featuring a non-magnetic body and a magnetic arrangement of alternating polarity permanent magnets, coupled with a drive arrangement for rotating the tool relative to the workpiece, achieving a frequency of at least 5 kHz to induce heating and hardening, and an integrated quenching system for efficient hardening and cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional copper coils or inductors are used for induction hardening, then hardening can be achieved, but the system requires dedicated tooling for each part geometry leading to high costs and low flexibility
Solution Approach 1:
The patent applies universality by using a single magnetic tool with adjustable parameters (rotational speed, number of poles, magnetic flux density) that can harden multiple different workpiece geometries. Unlike conventional dedicated inductors, this magnetic tool can be reconfigured for different parts without requiring custom-designed tooling for each geometry, thereby achieving multi-functionality and reducing tooling complexity.
Solution Approach 2:
The patent applies dynamics by making the magnetic tool rotatable with adjustable rotational speed and configurable pole arrangements. This dynamic capability allows the same magnetic tool to adapt to different workpiece geometries and hardening requirements, replacing static dedicated inductors and enabling flexibility across multiple part types.
2Reliability
If conventional induction heating systems are used, then hardening can be achieved, but electricity consumption is high increasing process cost
Solution Approach 1:
The patent applies parameter changes by utilizing permanent magnets to generate the magnetic field instead of consuming electrical power continuously. The system controls hardening parameters through mechanical rotational speed and magnetic pole configuration rather than high electrical power input, significantly reducing electricity consumption while maintaining effective induction hardening through the generated alternating magnetic flux.
3Manufacturing precision
If conventional induction heating systems are used, then hardening can be achieved, but dedicated tooling for each part leads to high costs
Solution Approach 1:
The patent applies universality by designing a single magnetic tool that can harden multiple different workpiece geometries with precise control. The adjustable rotational speed, pole configurations, and magnetic flux density allow the same tool to achieve manufacturing precision for various parts without requiring expensive dedicated tooling for each geometry.
Solution Approach 2:
The patent applies parameter changes by controlling hardening precision through adjustable parameters (rotational speed, number of poles, magnetic flux density) rather than through custom-designed dedicated tooling. This allows precise hardening control to be achieved through parameter adjustment rather than through complex dedicated apparatus design.
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 apparatus enables flexible and efficient hardening of various workpieces by adjusting the number of poles and rotational speed, reducing costs and energy consumption while maintaining high hardening quality through precise control of heating and quenching processes.
Implementation Method 1
A magnetic arrangement coupled to the body portion at or adjacent the surface of the body portion and configured to provide regions of alternating polarity
Implementation Method 2
A drive arrangement for rotating the magnetic tool relative to the workpiece holder about an axis of rotation is provided to induce heating of the workpiece to achieve a temperature in the austenitic range of the workpiece
Implementation Method 3
The apparatus includes a magnetic tool having a body portion formed of a generally non-magnetic material. The body portion has a surface configured to be positioned in close proximity to the workpiece being hardened
Data Source
AI summary
An apparatus for magnetic induction hardening of a workpiece includes a magnetic tool having a body portion formed of a generally non-magnetic material. The body portion has a surface configured to be positioned in close proximity to the workpiece being hardened. The apparatus further includes a magnetic arrangement coupled to the body portion at or adjacent the surface of the body portion and configured to provide regions of alternating polarity. A workpiece holder is configured to support the workpiece in close proximity to the surface of the magnetic tool. A drive arrangement for rotating the magnetic tool relative to the workpiece holder about an axis of rotation is provided to induce heating of the workpiece to achieve a temperature in the austenitic range of the workpiece resulting in hardening of the workpiece through a microstructural transformation.