Transverse Induction Coil Layout for Compact Uniform Heating
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Solution Overview
Problem
Existing transverse flux induction heating devices require an increase in length to enhance heating performance, which is inefficient and space-consuming.
Innovation Solution
The device incorporates an upper and lower inductor with coils and cores, where the coil has multiple turns, and conductor portions are arranged in slots with overlapping positions to increase heating performance without increasing length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a conventional longitudinal-type induction heating device is used, then the structure is simple, but the heating uniformity is poor and deformation occurs due to thermal expansion in one direction
Solution Approach 1:
The single longitudinal coil is divided into multiple transverse coils arranged side by side. Each transverse coil independently heats a specific section of the workpiece, ensuring uniform heat distribution across the entire surface and preventing localized overheating and deformation.
Solution Approach 2:
The heating arrangement transitions from a single-direction (longitudinal) coil to a multi-directional (transverse) coil configuration. This dimensional change allows heat to be applied from multiple directions simultaneously, achieving uniform heating without the thermal expansion deformation caused by unidirectional heating.
2Stability of the object's composition
If heating is applied from one direction only, then the device structure is simple, but the workpiece deforms due to uneven thermal expansion
Solution Approach 1:
The heating system is segmented into multiple independent transverse coils positioned at different locations. This segmentation allows each coil to heat a specific zone, distributing thermal expansion uniformly across the workpiece and preventing deformation from concentrated heat sources.
Solution Approach 2:
Different transverse coils are positioned to heat specific local areas of the workpiece according to the required heating pattern. This local quality approach ensures that each region receives appropriate heat treatment, maintaining dimensional stability while accommodating variations in heating requirements across the workpiece surface.
3Productivity
If a single coil is used for heating, then the device is simple to operate, but the heating efficiency is low and energy consumption is high
Solution Approach 1:
The single coil is segmented into multiple transverse coils that can be independently controlled. This allows simultaneous heating of multiple workpiece sections, significantly increasing heating efficiency and reducing the total energy required compared to sequential heating from a single coil.
Solution Approach 2:
Multiple transverse coils operate simultaneously to provide continuous heating across the entire workpiece surface. This eliminates idle time between heating different sections and maintains constant useful action, improving productivity while optimizing energy utilization.
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
This configuration achieves the required heating performance while maintaining a compact size, effectively addressing the inefficiencies of previous designs.
Implementation Method 1
induction heating coil (120) arranged in a transverse direction
Implementation Method 2
induction heating device for heating a workpiece (100) using electromagnetic induction
Implementation Method 3
heating elements arranged in a transverse direction with respect to the longitudinal direction of the material
Data Source
Figure 1
Figure 2
Figure 3
AI summary
In one slot (1121a, 1121b, 1221a, 1221b), first copper pipes (1111a to 1111f, 1211a to 1211f) and a second copper pipe (1111g, 1111h, 1211g, 1211h) are arranged. At each position (each y-coordinate) in a heating length direction in the one slot, the first copper pipe is at a position closest to a conductor plate M. In the one slot, the second copper pipe is at a position close to the conductor plate M relative to at least one first copper pipe. In the one slot, there is at least one second copper pipe electrically connected in series to the first copper pipe.