Variable Width Transverse Flux Induction Coil Design
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Solution Overview
Problem
Existing transverse flux electric induction coils are cumbersome and heavy due to large, flexible power connections and moveable assemblies, which are inefficient for heating conductive workpieces of varying widths and positions.
Innovation Solution
A transverse flux electric induction coil design featuring a fixed powered coil section combined with shorter, lightweight moveable passive coil sections that can adjust to accommodate workpieces of different widths and positions, using magnetic flux concentrators and flexible electrical connections to maintain efficient electromagnetic coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If moveable coil sections are made large to accommodate maximum workpiece width, then adaptability to different workpiece widths is improved, but weight and device complexity increase significantly
Solution Approach 1:
The coil assembly is divided into a fixed powered coil section and separate moveable passive coil sections. The passive sections can be independently positioned along the transverse axis to match different workpiece widths, while the powered section remains stationary and provides the primary electromagnetic field. This segmentation allows adaptability without requiring the entire coil assembly to be large and heavy.
Solution Approach 2:
Passive coil sections act as intermediaries between the powered coil section and the workpiece. These passive sections extend the magnetic flux path to cover wider areas when needed, but can be retracted or positioned only as far as required for each specific workpiece. The powered section generates the field, while passive sections modulate its spatial distribution without requiring full powered construction.
2Adaptability or versatility
If flexible power connections are provided for moveable coil sections, then adaptability to varying workpiece positions is improved, but device complexity and weight increase
Solution Approach 1:
The power connection requirement is extracted from the moveable passive coil sections and applied only to the fixed powered coil section. The passive sections are electrically isolated and derive their function through magnetic coupling with the powered section, eliminating the need for flexible power connections to moving parts. This removes the complexity of maintaining electrical contacts during movement.
Solution Approach 2:
The electrical connection function is replaced by magnetic field coupling. Instead of using mechanical flexible power connections to supply electricity to moveable sections, the invention uses electromagnetic induction where the powered section generates a magnetic field that induces currents in the passive sections. This substitutes a mechanical-electrical system with a purely electromagnetic interaction, eliminating wear and complexity of sliding contacts.
3Ease of operation
If moveable coil sections are made lightweight by reducing their length, then ease of movement is improved, but ability to maintain electromagnetic coupling over wide areas is reduced
Solution Approach 1:
The magnetic fields from the powered coil section and passive coil sections are merged to create a unified electromagnetic flux pattern across the workpiece area. The passive sections, though lightweight and short, are positioned to complement the powered section's field, with their combined effect providing consistent coupling over the required width. The fields add constructively rather than requiring individual sections to be oversized.
Solution Approach 2:
The passive coil sections are dynamically positioned based on the actual workpiece width and position requirements. Rather than being statically sized for maximum width, they are moved to the precise extent needed for each operation. This dynamic adjustment allows lightweight construction while maintaining optimal coupling efficiency for each specific workpiece, as the sections are never positioned farther than necessary.
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 design allows for efficient inductive heating of conductive workpieces by adjusting to varying widths and positions, reducing weight and complexity while maintaining effective electromagnetic coupling, thus improving heating efficiency and flexibility.
Implementation Method 1
a fixed powered coil section and two moveable passive coil sections, the moveable passive coil sections being slidably connected to the fixed powered coil section so as to be movable in a transverse direction relative to the fixed powered coil section along which the edges of the workpiece move, wherein the moveable passive coil sections are electrically isolated from the fixed powered coil section, wherein alternating current flows through the fixed powered coil section and generates an alternating magnetic flux therearound, and wherein the alternating magnetic flux generated by the fixed powered coil section magnetically couples with the moveable passive coil sections to induce a current flow in the moveable passive coil sections
Implementation Method 2
the alternating magnetic flux generated by the fixed powered coil section magnetically couples with the moveable passive coil sections to induce a current flow in the moveable passive coil sections
Implementation Method 3
efficient inductive heating of conductive workpieces
Data Source
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AI summary
A variable width transverse flux electric inductor has a fixed powered coil section and associated box-like moveable passive coil sections that electromagnetically couple with magnetic flux generated by current flowing through the fixed powered section. The passive coil sections can be transversely moved across the workpiece to accommodate induction heating of workpieces having different widths or track movement of the workpiece. Alternatively the fixed powered coil section and associated moveable coil sections may be connected to each other through flexible connections, sliding contacts or other means, such as clamps, so that an electrical connection can be maintained between both in any relative position.