Segmented Primary Coil Traverse Hardening
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Solution Overview
Problem
Existing traverse hardening devices face challenges in efficiently heating shaft-like bodies with varying diameters due to overheating phenomena at diameter change corners, requiring complex mechanisms to position secondary coils effectively.
Innovation Solution
A traverse hardening device utilizing a primary coil with a specific cross-sectional shape, segmented in a matrix form, allows for uniform heating of shaft-like bodies with varying diameters without the need for secondary coils, thereby minimizing overheating at diameter change corners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a secondary coil member is added to heat the small diameter part uniformly, then heating uniformity is improved, but device complexity increases
Solution Approach 1:
The primary coil is divided into multiple independent coil units arranged in the axial direction, each capable of being independently controlled. This segmentation allows different regions of the shaft-like body to be heated with appropriate power levels, achieving uniform heating without requiring additional secondary coils.
Solution Approach 2:
Different coil units are assigned different power levels based on the local heating requirements of various diameter regions. The control unit adjusts the power supplied to each coil unit individually, providing localized heating quality that matches the specific needs of each section of the shaft-like body.
2Use of energy by moving object
If the primary coil is positioned close to the shaft-like body for efficient heating, then heating efficiency is improved, but overheating occurs at diameter change corners
Solution Approach 1:
The primary coil is segmented into multiple coil units that can be independently controlled. This allows the system to apply different power levels to different axial positions, preventing overheating at diameter change corners while maintaining efficient heating in other regions.
Solution Approach 2:
The power supplied to each coil unit is dynamically adjusted based on the local diameter and heating requirements. The control unit modifies the power distribution in real-time as the coil traverses the shaft-like body, adapting to changing geometric conditions to prevent overheating while maintaining efficiency.
3Manufacturing precision
If multiple coil members are concentrically disposed to achieve uniform heating, then heating uniformity is improved, but device complexity and current requirements increase
Solution Approach 1:
Instead of using multiple concentric coils, the invention uses a single primary coil segmented into multiple axial units. Each unit can be independently controlled to provide the necessary heating uniformity without requiring the complex concentric multi-coil structure.
Solution Approach 2:
Rather than adding more coils concentrically to achieve uniform heating, the invention inverts the approach by segmenting a single coil axially and controlling each segment independently. This reduces device complexity while achieving the same heating uniformity goal.
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 efficient and uniform hardening of shaft-like bodies with varying diameters using a relatively simple device constitution, minimizing overheating and ensuring effective heating to the required temperature for hardening.
Implementation Method 1
a high-frequency current is caused to flow in the primary coil member to heat the shaft-like body using induction heating
Implementation Method 2
a shaft-like body has been subjected to traverse hardening by induction heating
Implementation Method 3
a cross-sectional image of the primary coil which appears in a plane orthogonal to a circumferential direction of the primary coil appears in a form of segmentations by a matrix of 2 pieces vertically×2 pieces horizontally
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
This traverse hardening device is for performing traverse hardening of a shaft-like body having a main body part and a small diameter part that is provided to an intermediate section of the main body part in an axial direction and that has a smaller outer diameter than the main body part. The traverse hardening device includes a primary coil, an electric current supply device, a uniaxial actuator, and a control device. In addition, when a horizontal axis represents a radial direction of the primary coil in a plane orthogonal to a circumferential direction of the primary coil and a vertical axis represents a direction orthogonal to the radial direction, a cross-section image of the primary coil which appears on the plane appears in a form of segmentations by a matrix of m pieces vertically×n pieces horizontally (m and n are each an integer of 2 or more than 2).