Segmented Heat Shield Assembly for Curved Induction Welding
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Solution Overview
Problem
Induction welding faces challenges in maintaining precise temperature control to prevent surface burning while ensuring a melting temperature at the bond line between workpiece members, as existing technologies struggle to effectively manage heat distribution during the welding process.
Innovation Solution
An induction welding assembly is introduced, comprising an induction welding coil and a heat shield assembly with multiple heat shields that are aligned end-to-end, providing a recess for the coil to move along a curved path. This assembly maintains a constant spacing between the coil and the heat shields, ensuring uniform heat distribution and preventing surface damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single heat shield is used, then the structure is simple, but the welding path control and heat distribution uniformity are insufficient
Solution Approach 1:
The heat shield is divided into multiple segments (first heat shield, second heat shield, third heat shield) arranged in sequence along the welding path. Each segment can be independently positioned and adjusted, allowing precise control of the welding path while maintaining manageable structural complexity. The segments are connected through positioning features such as recesses and protrusions that enable accurate alignment.
Solution Approach 2:
The heat shield segments are arranged in a three-dimensional configuration along the curved welding path, rather than a single linear arrangement. This spatial distribution allows the heat shield to follow complex welding trajectories while maintaining consistent spacing between the heat shield and workpiece, improving welding path control without excessive complexity.
2Productivity
If the induction welding coil is moved closer to the workpiece, then welding efficiency increases, but surface burning occurs
Solution Approach 1:
The heat shield acts as an intermediary component positioned between the induction welding coil and the workpiece surface. It selectively blocks electromagnetic radiation from reaching areas that would otherwise burn, while allowing the coil to operate at optimal proximity for efficient welding. The heat shield thus mediates between the conflicting requirements of welding efficiency and surface protection.
Solution Approach 2:
The heat shield provides localized protection only in areas where surface burning would occur, rather than uniformly shielding the entire workpiece. The segmented design allows different portions of the heat shield to be positioned strategically to protect specific high-risk areas while leaving other areas exposed to beneficial heat for welding.
3Temperature
If multiple heat shields are used, then heat distribution and temperature control improve, but device complexity increases
Solution Approach 1:
Multiple heat shield segments are merged into a coordinated assembly that functions as a unified system. The segments share common positioning features, connection mechanisms, and control systems, allowing them to work together to improve temperature control while minimizing the complexity increase that would result from treating them as separate independent components.
Solution Approach 2:
The heat shield segments are designed to maintain consistent spacing and positioning relative to the workpiece throughout the welding path, creating equipotential conditions for heat distribution. This uniform positioning ensures consistent temperature control across different sections of the weld while using standardized segment designs that reduce overall complexity.
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 solution effectively manages temperature control, preventing surface burning and ensuring a strong bond between workpiece members by maintaining consistent heat distribution and spacing, thereby enhancing the efficiency and reliability of the induction welding process.
Implementation Method 1
induction welding coil... operated to induction weld the first workpiece member to the second workpiece member
Implementation Method 2
induction welding... maintaining a melting temperature at the bond line between an adjacent pair of workpiece members
Implementation Method 3
heat shield assembly... preventing surface burning... managing heat distribution during the welding process
Data Source
AI summary
An assembly is provided for induction welding. This assembly utilizes a plurality of heat shields (e.g., mica heat shields) that are aligned/disposed in end-to-end relation, with each such heat shield having a recess. An induction welding coil may be disposed within a heat shield recess during induction welding operations and is movable along a welding path while proceeding along the recesses of the various heat shields. This welding path may be axially extending or may be curved. The induction welding assembly may be used to induction weld a stiffener to a curved skin or shell, for instance where a base of the recess for each heat shield is curved such that the induction welding coil may be moved along a curved welding path and while maintaining a constant spacing between the induction welding coil and the recess base of the various heat shields.