Welding Device Inductor Segmentation for Uniform Pre-Heating
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Solution Overview
Problem
Existing welding technologies face challenges in uniformly pre-heating the circumference of workpieces, leading to undesirable stress and uneven heating, particularly around the weld seam, which can result in material tears and reduced welding quality.
Innovation Solution
A welding device equipped with a separate heating device, such as an electromagnetic inductor, that can be moved relative to the workpiece to provide uniform pre-heating and reheating, allowing for precise temperature control and automation of the welding process, including the use of a laser welding head that operates independently of the inductor's magnetic field.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If an inductor is used for pre-heating the workpiece, then heating capability is improved, but uniform heating of the entire circumference is not achieved, leading to undesirable stress
Solution Approach 1:
The inductor is divided into multiple independent heating zones along its length, each capable of being controlled separately. This segmentation allows different sections of the workpiece circumference to be heated uniformly and independently, eliminating the stress problems caused by uneven heating while maintaining effective pre-heating capability.
2Area of stationary object
If the workpiece is threaded through the inductor for pre-heating, then heating coverage is improved, but the workpiece can only be conveyed along its longitudinal extension
Solution Approach 1:
The inductor is designed with a radial opening that allows workpieces to be introduced not only along the longitudinal axis but also from radial directions. This dimensional flexibility enables various workpiece configurations and assembly operations while maintaining comprehensive heating coverage through the segmented heating zones.
3Manufacturing precision
If a separate heating device is added to the welding device, then welding quality is improved, but device complexity increases
Solution Approach 1:
The heating device is integrated into the welding device housing, with the inductor embedded within the same structure. The control unit for the heating device is merged with the welding device's control system, allowing coordinated operation. This integration improves welding quality through controlled pre-heating while minimizing the increase in device complexity through unified design.
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 solution ensures uniform heating around the weld seam, reducing the risk of material tears, improving welding quality, and allowing for easier workpiece handling and automation, while maintaining energy efficiency and preventing quench cracking.
Implementation Method 1
the inductor (5) comprises at least two inductor parts (6, 7) which can be moved relative to one another into a working position enclosing a workpiece to be welded (3)
Implementation Method 2
heating the workpiece (3) by means of the inductor (5)
Data Source
AI summary
The invention relates to a welding device (1), in particular a laser welding device, for welding metal workpieces (3) by means of at least one welding head (2), in particular a laser welding head, which defines a working area (4). The welding device is characterized by at least one heating device (5) which acts on the working area (4) to heat up the workpiece (3), in particular before and/or after the welding process.