Turntable Brazing with Indirect Heating and Rapid Cooling
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Solution Overview
Problem
Conventional brazing methods face issues such as damage to base materials and bonding objects due to excessive heat, inefficient energy use, and prolonged processing times, which can lead to structural destruction and increased energy consumption.
Innovation Solution
A brazing system and method that includes a turntable, base material and brazing filler metal supply devices, a first heating device for bonding the filler metal to the base material, a second heating device for bonding the object to the base material by electrically heating it, and a cooling device to quickly cool the bonding object, thereby minimizing heat exposure and reducing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the temperature for heating the brazing filler metal is excessively high or the heating time is prolonged, then the brazing filler metal can be properly melted and bonded, but the internal structure of the base metal or bonding object is destroyed
Solution Approach 1:
The patent introduces a susceptor as an intermediary material that absorbs electromagnetic energy and converts it to heat, which then transfers to the base material and brazing filler metal. This indirect heating method through the susceptor allows for controlled temperature rise, preventing excessive thermal damage while ensuring proper bonding. The susceptor acts as a mediator between the electromagnetic field and the materials being bonded.
Solution Approach 2:
The patent replaces conventional thermal conduction heating with electromagnetic induction heating. Instead of using direct contact heating elements that transfer heat through conduction, the system uses an electromagnetic field generated by a coil to induce eddy currents in the susceptor, which then generates heat through resistive heating. This substitution enables more precise and controllable heating, reducing thermal damage.
2Productivity
If direct heating of the bonding object is used to melt the brazing filler metal, then the bonding process can be completed, but the bonding object is damaged in the process
Solution Approach 1:
The susceptor serves as an intermediary that absorbs the electromagnetic energy and converts it to thermal energy, which then heats the brazing filler metal and base material indirectly. This prevents direct exposure of the bonding object to intense electromagnetic fields and excessive heat, reducing damage while maintaining process effectiveness.
Solution Approach 2:
The patent changes the heating parameter from direct electromagnetic radiation or contact heating to indirect heating through electromagnetic induction in the susceptor. This parameter change allows for more controlled and uniform heat distribution, preventing localized overheating and damage to the bonding object while ensuring the brazing filler metal reaches its melting point.
3Reliability
If conventional brazing heating methods are used, then the brazing filler metal can be melted, but energy consumption is high and process time is prolonged
Solution Approach 1:
The patent replaces conventional thermal conduction and convection heating systems with electromagnetic induction heating. The electromagnetic field directly induces currents in the susceptor, converting electrical energy to thermal energy with high efficiency. This eliminates energy losses associated with heating large zones or prolonged heat transfer through intermediaries, significantly reducing energy consumption and process time.
Solution Approach 2:
The electromagnetic induction heating operates through periodic alternating current in the coil, creating oscillating electromagnetic fields that continuously induce eddy currents in the susceptor. This periodic action ensures efficient and uniform heating, reducing the overall process time and energy consumption compared to continuous conventional heating methods.
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 system prevents damage to base materials and bonding objects by controlling temperature, reduces energy consumption, and shortens processing time, resulting in cost-effective and efficient brazing operations.
Implementation Method 1
a second heating device which is in contact with opposite sides of the base material to fix the base material and is provided with electrodes for supplying electric current to the base material so as to bond the object to be bonded to the base material
Implementation Method 2
a cooling device which comes into contact with the object to be bonded to cool the object to be bonded
Data Source
AI summary
A brazing system according to an embodiment of the present invention, which is for brazing an object to be bonded to a base material, comprises: a turntable provided with a reception part for receiving the base material and rotatable clockwise or counterclockwise; a base material supply device for supplying the base material to the reception part; a brazing filler metal supply device for supplying a brazing filler metal to an upper side of the base material; a first heating device for bonding the brazing filler metal to the base material; a bonding object supply device for supplying the object to be bonded to an upper side of the brazing filler metal bonded to the base material; a second heating device which is in contact with opposite sides of the base material to fix the base material and is provided with electrodes for supplying electric current to the base material so as to bond the object to be bonded to the base material; and a cooling device which comes into contact with the object to be bonded to cool the object to be bonded.