Segmented Induction Heating Coil for Stepped Workpieces
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Solution Overview
Problem
Induction heating efficiency is reduced by increased gaps between the induction heating coil and workpiece, and existing coils struggle to uniformly heat double-side-stepped workpieces due to fixed magnetic field configurations.
Innovation Solution
An induction heating coil with a primary coil and a removable ring-shaped secondary coil, where the secondary coil forms a closed circuit and can be easily adjusted to accommodate different workpiece portions, allowing for localized temperature control and efficient heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a conductor extends parallel with the outer line of the cross section of the workpiece to minimize gap, then the workpiece can be set in and removed easily, but the magnetic field cannot be adjusted locally for uniform heating
Solution Approach 1:
The induction heating coil is divided into multiple independent coil sections (first coil section, second coil section, third coil section) along the axial direction. Each section can generate independent magnetic fields that are controlled separately, allowing local adjustment of heating intensity for different portions of the workpiece while maintaining the overall cylindrical structure for easy workpiece insertion and removal.
Solution Approach 2:
Different coil sections are positioned at different radial distances from the workpiece center, creating localized magnetic field zones with different intensities. The first coil section is closer to the workpiece for stronger heating, while the second and third sections provide supplementary heating, enabling precise control of temperature distribution across the workpiece surface.
2Device complexity
If the induction heating coil has a fixed configuration, then the structure is simple, but it cannot accommodate double-side-stepped workpieces with varying diameters effectively
Solution Approach 1:
The coil is segmented into multiple sections with different radial positions and winding densities. This segmentation allows each section to adapt to different portions of the stepped workpiece geometry while maintaining a relatively simple overall cylindrical structure that is easy to manufacture and operate.
Solution Approach 2:
The coil design adds radial dimensionality by positioning coil sections at different distances from the workpiece center, rather than using a single uniform coil. This multi-level radial arrangement enables the coil to conform to the varying diameter of double-side-stepped workpieces while keeping the structural configuration manageable.
3Device complexity
If a single uniform coil is used, then the device is simple, but the heating efficiency decreases for workpieces with varying cross-sections
Solution Approach 1:
The coil is divided into multiple sections with optimized winding densities and radial positions. This segmentation allows each section to be optimally positioned for heating specific portions of the workpiece, maximizing magnetic flux coupling and heating efficiency while avoiding the energy losses that would occur with a single uniform coil 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 solution enables uniform and efficient heating of double-side-stepped workpieces by minimizing the gap between the coil and workpiece, allowing easy setup and removal, and enabling adjustable magnetic fields for precise temperature control.
Implementation Method 1
a conductor extends parallel with an outer line of a cross section, including its center axis, of a workpiece, and generates a magnetic flux when supplied with high-frequency power
Implementation Method 2
The workpiece is inductively heated receiving the magnetic flux generated by the induction heating coil
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
An induction heating coil (3) has a primary coil (4) to which electric power is supplied and a ring-shaped secondary coil (5) forming a closed circuit. The primary coil (4) has a base-side portion that covers an outer periphery of the secondary coil (5) and a distal-side portion extending from the base-side portion in the center axis direction of the secondary coil (5) in a state in which the base-side portion covers the secondary coil (5). The opening width of the base-side portion is greater than the opening width of the distal-side portion. The secondary coil (5) is provided such that it can be inserted into and removed from the inside of the primary coil (4) from the base-side portion of the primary coil (4).