Triplex Furnace Heating for Uniform Motor Stator Temperature
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Solution Overview
Problem
Existing methods for heating electric motor stators and rotors made of different materials, such as steel and copper, are inefficient, time-consuming, and result in non-uniform temperature distribution, leading to energy waste and equipment inflexibility.
Innovation Solution
A triplex furnace system that simultaneously uses induction, IR radiation, and convection heating, with movable heating elements that adapt to component size and shape, ensuring uniform heating from inside and outside, and controlled temperature distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If forced convection furnaces are used for heating stators, then the heating process is gentle and insensitive to long dwell times, but it requires considerable time, space, and energy
Solution Approach 1:
The patent combines three different heating methods (induction heating, infrared radiation, and forced convection) into a single triplex furnace system. This allows simultaneous application of multiple heating mechanisms to achieve both fast heating and uniform temperature distribution, resolving the contradiction between heating speed and heating quality
Solution Approach 2:
The triplex furnace is designed to perform multiple heating functions using different physical principles. The system can switch between or combine induction heating for rapid temperature rise, infrared radiation for surface heating, and forced convection for uniform temperature distribution, making it universally applicable to various heating requirements
2Productivity
If infrared radiation is used for tempering stators, then heat transfer through air is eliminated and heating is direct, but surfaces of different materials are heated differently depending on reflectance and thermal conductivity
Solution Approach 1:
The patent combines infrared radiation with forced convection heating. The infrared radiation provides rapid surface heating while the forced convection system circulates hot air to ensure uniform temperature distribution throughout the stator, compensating for the non-uniform heating effect of infrared radiation on different materials
Solution Approach 2:
The patent introduces air as an intermediary heat transfer medium between the infrared radiation source and the stator. The forced convection system circulates this heated air to distribute heat uniformly across all surfaces, including those with different reflectance properties, thereby achieving temperature uniformity
3Productivity
If induction furnaces are used for heating magnetic materials, then heating is efficient and direct, but copper parts are not heated and hot spots occur at corners and edges
Solution Approach 1:
The patent combines induction heating with forced convection heating. The induction heating provides efficient direct heating of magnetic materials while the forced convection system circulates hot air to heat non-magnetic parts and distribute heat uniformly, preventing hot spots at corners and edges
Solution Approach 2:
The patent introduces air circulation as an intermediary to transfer heat from the induction-heated regions to the non-magnetic copper parts and to distribute heat uniformly throughout the stator, preventing localized overheating at corners and edges
4Productivity
If multiple workpiece carriers are used to reduce tempering time, then throughput increases, but the plant becomes inflexible and expensive
Solution Approach 1:
The patent applies preliminary action by using induction heating to rapidly pre-heat the stator before the impregnation process. This reduces the overall tempering time required, allowing single workpiece carriers to be used while maintaining high throughput, thus avoiding the complexity and cost of multiple carriers
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
Enables quick, energy-efficient, and precise heating with minimal space requirements, maintaining uniform temperature distribution and reducing energy consumption.
Implementation Method 1
an inductor (8) arranged on the outside for inductive heating, in particular of the laminated core
Implementation Method 2
inductive heating is performed by means of electromagnetic fields of different frequencies
Implementation Method 3
at least one infrared radiator (9) positioned in the central bore of the stator (7) for heating the copper rods
Implementation Method 4
for convective heating of the thermal chamber (2) and thus of the component
Data Source
AI summary
Multiple temperature-control process for stators (7) and rotors of electric motors and components consisting of materials with different magnetic properties by means of a triplex furnace (1) for the quick, efficient, and uniform heating-up of preferably tubular components such as stators (7), wherein the magnetic parts of a component are primarily heated up by means of induction and at the same time non-magnetic parts of the same component are primarily heated up by means of infrared radiation, and at the same time and subsequently secondary heating takes place by means of convection, in particular by passive heating elements (10), which serves for finely adjusting the target temperature and for maintaining it.