Transverse Flux Induction Heating for Discrete Workpieces

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Solution Overview

Problem

Existing electric induction heat treatment methods for conductive articles require higher magnetic field intensities and are inefficient for articles with specific orientations, such as closed bottom cylindrically shaped hollow preforms and planarly-oriented workpieces, as they rely on vertically oriented magnetic flux.

Innovation Solution

The use of a series magnetic loop circuit formed from open-box rectangular ferromagnetic material with longitudinally-oriented through-gaps and inductors positioned around these gaps to establish a transverse magnetic flux, allowing workpieces to be positioned with their longitudinal axis parallel or orthogonal to the flux for efficient heating.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If vertically oriented magnetic flux is used for heating conductive articles, then the heating process can be simplified, but higher magnetic field intensities are required and heating efficiency is reduced for articles with specific orientations

Engineering Contradiction:

Improveheating process simplicityVSAvoidheating efficiency

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The patent inverts the conventional vertical magnetic flux orientation to use horizontal transverse flux orientation. The magnetic flux is now applied perpendicular to the longitudinal axis of cylindrical workpieces rather than parallel to it, fundamentally changing the heating mechanism to overcome the limitations of high conductivity paths in vertically oriented systems.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent changes the orientation parameter of the magnetic flux from vertical to horizontal (transverse), and adjusts the flux direction to be perpendicular or at an angle to the workpiece longitudinal axis. This parameter change optimizes the magnetic coupling with the workpiece, reducing the required field intensity while improving heating efficiency.

Inventive Principle:

Principle #35Parameter changes

2Device complexity

If vertically oriented magnetic flux is used, then the apparatus structure can be simplified, but the adaptability to different workpiece orientations and geometries is limited

Engineering Contradiction:

Improveapparatus structureVSAvoidworkpiece orientation adaptability

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The transverse flux induction heating apparatus is designed to handle multiple workpiece types and orientations using the same basic structure. By orienting the magnetic flux transversely, the system can effectively heat cylindrical workpieces whether their longitudinal axes are perpendicular or parallel to the flux direction, making the apparatus universally applicable to various geometries without requiring complex reconfiguration.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

Instead of adapting the workpiece orientation to match a fixed vertical flux direction, the patent inverts the approach by fixing the workpiece orientation and adapting the flux direction to be transverse and perpendicular to the workpiece axis. This inversion provides greater versatility for handling different workpiece geometries.

Inventive Principle:

Principle #13The other way round (Inversion)

3Temperature

If higher magnetic field intensities are applied to heat highly conductive articles, then heating can be achieved, but energy consumption increases and system complexity increases

Engineering Contradiction:

Improveworkpiece heatingVSAvoidenergy consumption

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

The patent changes the magnetic flux orientation parameter from vertical to transverse-horizontal, and positions the flux to be perpendicular to the workpiece longitudinal axis. This parameter optimization creates more effective magnetic coupling with the conductive material, achieving the required heating temperature with lower field intensities and reduced energy consumption.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the conventional vertical flux induction heating mechanism with a transverse flux mechanism. This substitution fundamentally changes how magnetic energy couples with the workpiece, using the transverse orientation to create more efficient eddy currents that generate heat with lower input energy requirements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 approach achieves higher efficiency in heating conductive articles by optimizing the orientation of the magnetic flux relative to the workpiece, enhancing heating performance for articles with varying geometries, including closed bottom cylindrical and planarly-oriented workpieces.

Implementation Method 1

Inductors are positioned around the open-box rectangular ferromagnetic material adjacent to a side of each longitudinally-oriented workpiece through-gap. An alternating current power supply is connected to the inductors to establish a transverse magnetic flux in each one of the longitudinally-oriented workpiece through-gaps

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

electric induction heat treatment of a discrete workpiece in a gap of a magnetic circuit

Methodology Applied

Scientific EffectInduction heating: Induction Heating

Data Source

PatentUS10477628B2Transverse flux electric induction heat treatment of a discrete workpiece in a gap of a magnetic circuit

Publication Date: 2019.11.12 RADYNE CORP

AI summary

Discrete workpieces move through a longitudinally-oriented through-gap in an open-box rectangular ferromagnetic material. A transverse magnetic flux established in the through-gap inductively heats the discrete workpieces moving through the longitudinally-oriented through-gap. A longitudinal axis of the workpiece or the planar surface of a planarly-oriented workpiece is oriented either parallel to, or perpendicular to, the transverse magnetic flux to heat treat the workpiece.