Travel Sensor Assembly for Feedback-Controlled Induction Heating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional induction heating methods for pre-heating weld paths, especially in pipe welding, face challenges with stationary workpieces and lack temperature and travel feedback control, leading to inefficiencies and potential cracks due to inadequate filler metal binding.
Innovation Solution
An induction heating system with a moveable head assembly, temperature sensor, and travel sensor, which uses a power source to control the induction heating head's movement and heat application based on real-time temperature and position feedback, eliminating the need for transformers and ensuring consistent heat distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional induction heating blankets or fixed-position welders are used, then heating can be applied to stationary workpieces, but the system cannot effectively handle moving workpieces or provide temperature feedback control
Solution Approach 1:
The induction heating system transitions from a static blanket design to a dynamic moveable head assembly that can track and follow the movement of workpieces. The head assembly includes motors, sensors, and control systems that enable it to dynamically adjust its position and maintain optimal heating parameters while the workpiece moves through the system.
Solution Approach 2:
The system incorporates temperature sensors and position sensors that provide real-time feedback to the control system. This feedback loop allows the system to monitor the actual temperature and position of the workpiece and adjust the heating power and head position accordingly, ensuring consistent heating quality even as the workpiece moves.
2Productivity
If rosebuds or conventional heating devices are used, then pre-heating can be applied, but the process takes a relatively long period of time
Solution Approach 1:
The moveable head assembly enables continuous heating action as it follows the workpiece through its entire path. Instead of heating discrete stationary points sequentially, the system maintains continuous thermal input on the moving workpiece, eliminating idle time between heating zones and significantly reducing total pre-heating duration.
3Adaptability or versatility
If induction heating blankets are used with rotating pipes, then heating can be applied, but the cables may roll up or wear through the insulation
Solution Approach 1:
The system replaces the mechanical cable-based power transmission with a wireless or rigid conduit-based power delivery system. This eliminates the flexible cables that are prone to rolling and insulation wear, while maintaining the ability to power the induction heating elements on moving and rotating workpieces.
4Ease of operation
If conventional heating devices are placed at one location and then moved, then heating can be applied to different positions, but there is no travel feedback for controlling the power source
Solution Approach 1:
The system incorporates position sensors and travel feedback mechanisms that continuously monitor the location of the moveable head assembly and the workpiece. This position data is fed back to the control system, which uses it to precisely control the heating power output and timing, ensuring consistent heating quality across different positions without manual intervention.
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 system enables efficient pre-heating and post-heating of moving workpieces by providing precise temperature control and heat distribution, reducing the risk of cracks and improving filler metal binding, thus enhancing welding quality.
Implementation Method 1
an induction heating head assembly (14) having a coil tuned to the power source and configured to induce heat in the workpiece without a transformer
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
An induction heating system includes an induction heating head assembly configured to move relative to a workpiece. The induction heating system may also include a temperature sensor assembly configured to detect a temperature of the workpiece and/or a travel sensor assembly configured to detect a position, movement, or direction of movement of the induction heating head assembly relative to the workpiece, and to transmit feedback signals to a controller configured to adjust the power provided to the induction heating head assembly by a power source based at least in part on the feedback signals. In certain embodiments, the induction heating system may also include a connection box configured to receive the feedback signals, to perform certain conversions of the feedback signals, and to provide the feedback signals to the power source. Furthermore, in certain embodiments, the induction heating system may include an inductor stand assembly configured to hold the induction heating head assembly against the workpiece.