Patent Grant
10986702
This disclosure relates generally to induction heating, and more particularly to induction heating using an array of induction heating cells.
Induction heating uses an electrically conducting object to heat a part using electromagnetic induction through heat generated in the electrically conducting object by eddy currents. In certain environments, induction heating may be used to heat a part having a planar surface. In such environments, the electrically conducting object is shaped to match the planar surface. The use of induction heating on parts having non-planar surfaces may be inefficient because a shape of the electrically conducting object does not match a shape of the surface of a part to be heated.
The subject matter of the present application has been developed in response to the present state of the art, and in particular, in response to shortcomings of conventional apparatuses used for induction heating, particularly induction heating of parts for the purpose of curing or heat treating the parts. For example, conventional apparatuses do not facilitate use on non-planar surfaces.
Accordingly, the subject matter of the present application has been developed to provide an apparatus, system, and method that overcome at least some of the above-discussed shortcomings of prior art techniques. More particularly, in some embodiments, described herein are apparatuses, systems, and methods for induction heating, such as induction heating of a part for curing the part, that include multiple inducting heating cells that move relative to one another to conform to non-planar surfaces.
An apparatus for induction heating includes a plurality of induction heating cells attachably coupled together. Each induction heating cell of the plurality of induction heating cells is movable relative to adjacent induction heating cells of the plurality of induction heating cells to conform the plurality of induction heating cells to a non-planar surface. Each induction heating cell of the plurality of induction heating cells includes a power connector and a coupling feature to couple the respective induction heating cell with one or more other induction heating cells of the plurality of induction heating cells. The preceding subject matter of this paragraph characterizes example 1 of the present disclosure.
The coupling feature includes at least one hinge. The preceding subject matter of this paragraph characterizes example 2 of the present disclosure, wherein example 2 also includes the subject matter according to example 1, above.
The coupling feature includes at least one wire. The preceding subject matter of this paragraph characterizes example 3 of the present disclosure, wherein example 3 also includes the subject matter according to any one of examples 1 or 2, above.
Each induction heating cell of the plurality of induction heating cells includes a data connector. The preceding subject matter of this paragraph characterizes example 4 of the present disclosure, wherein example 4 also includes the subject matter according to any one of examples 1, 2, or 3, above.
The power connector and data connector are integrated together. The preceding subject matter of this paragraph characterizes example 5 of the present disclosure, wherein example 5 also includes the subject matter according to any one of examples 1, 2, 3, or 4, above.
The power connector includes a plurality of power connectors. The preceding subject matter of this paragraph characterizes example 6 of the present disclosure, wherein example 6 also includes the subject matter according to any one of examples 1, 2, 3, 4, or 5, above.
The coupling feature includes a plurality of apertures. The preceding subject matter of this paragraph characterizes example 7 of the present disclosure, wherein example 7 also includes the subject matter according to any one of examples 1, 2, 3, 4, 5, or 6, above.
Each induction heating cell of the plurality of induction heating cells includes a thermocouple, a frequency detection sensor and port, or some combination thereof. The preceding subject matter of this paragraph characterizes example 8 of the present disclosure, wherein example 8 also includes the subject matter according to any one of examples 1, 2, 3, 4, 5, 6, or 7, above.
Each induction heating cell of the plurality of induction heating cells is individually controllable to provide induction heating. The preceding subject matter of this paragraph characterizes example 9 of the present disclosure, wherein example 9 also includes the subject matter according to any one of examples 1, 2, 3, 4, 5, 6, 7, or 8, above.
Each induction heating cell of the plurality of induction heating cells includes a coil disposed circumferentially on an electrically conductive plate, and a housing enclosing at least a portion of the electrically conductive plate. The preceding subject matter of this paragraph characterizes example 10 of the present disclosure, wherein example 10 also includes the subject matter according to any one of examples 1, 2, 3, 4, 5, 6, 7, 8, or 9, above.
Each induction heating cell of the plurality of induction heating cells includes a coil disposed in a housing. The preceding subject matter of this paragraph characterizes example 11 of the present disclosure, wherein example 11 also includes the subject matter according to any one of examples 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10, above.
Each induction heating cell of the plurality of induction heating cells is controllable to a selected temperature, a selected frequency, a selected power, or some combination thereof. The preceding subject matter of this paragraph characterizes example 12 of the present disclosure, wherein example 12 also includes the subject matter according to any one of examples 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or 11, above.
A system for controlling an array of induction heating cells includes a feedback reception device that receives temperature and frequency feedback from each induction heating cell of the array of induction heating cells. Each induction heating cell of the array of induction heating cells is movable relative to adjacent induction heating cells of the array of induction heating cells to conform the array of induction heating cells to a non-planar surface. The system also includes one or more induction generators that provide power, frequency, or a combination thereof to each induction heating cell of the array of induction heating cells. The system includes a controller that controls the one or more induction generators based on the temperature and frequency feedback. The preceding subject matter of this paragraph characterizes example 13 of the present disclosure.
The one or more induction generators include a plurality of induction generators. The preceding subject matter of this paragraph characterizes example 14 of the present disclosure, wherein example 14 also includes the subject matter according to example 13, above.
Each induction generator of the plurality of induction generators is coupled to a respective induction heating cell of the array of induction heating cells. The preceding subject matter of this paragraph characterizes example 15 of the present disclosure, wherein example 15 also includes the subject matter according to any one of examples 13 or 14, above.
The one or more induction generators are frequency matching induction generators that match a frequency corresponding to one or more induction heating cells of the array of induction heating cells, a material being heated, a tool comprising the array of induction heating cells, or some combination thereof. The preceding subject matter of this paragraph characterizes example 16 of the present disclosure, wherein example 16 also includes the subject matter according to any one of examples 13, 14, or 15, above.
The one or more induction generators include a frequency matching induction generator that matches a frequency corresponding collectively to the array of induction heating cells. The preceding subject matter of this paragraph characterizes example 17 of the present disclosure, wherein example 17 also includes the subject matter according to any one of examples 13, 14, 15, or 16, above.
The one or more induction generators include a frequency matching induction generator that produces a plurality of frequency outputs that are selectively provided to corresponding induction heating cells of the array of induction heating cells. The preceding subject matter of this paragraph characterizes example 18 of the present disclosure, wherein example 18 also includes the subject matter according to any one of examples 13, 14, 15, 16, or 17, above.
A method for induction heating includes providing power, frequency, or a combination thereof to one or more induction heating cells of a plurality of induction heating cells. Each induction heating cell of the plurality of induction heating cells includes a connector for receiving power, frequency, or a combination thereof and a coupling feature to movably couple the respective induction heating cell with one or more other induction heating cells of the plurality of induction heating cells to facilitate conforming the plurality of induction heating cells to a non-planar surface. The method also includes receiving feedback from the one or more induction heating cells of the plurality of induction heating cells. The method includes adjusting the power, the frequency, or a combination thereof provided to the one or more induction heating cells of the plurality of induction heating cells in response to receiving the feedback from the one or more induction heating cells of the plurality of induction heating cells. The preceding subject matter of this paragraph characterizes example 19 of the present disclosure.
Adjusting the power, the frequency, or a combination thereof provided to the one or more induction heating cells of the plurality of induction heating cells includes individually controlling the one or more induction heating cells of the plurality of induction heating cells to a selected temperature, a selected frequency, a selected power, or some combination thereof. The preceding subject matter of this paragraph characterizes example 20 of the present disclosure, wherein example 20 also includes the subject matter according to example 19, above.
The described features, structures, advantages, and/or characteristics of the subject matter of the present disclosure may be combined in any suitable manner in one or more embodiments and/or implementations. In the following description, numerous specific details are provided to impart a thorough understanding of embodiments of the subject matter of the present disclosure. One skilled in the relevant art will recognize that the subject matter of the present disclosure may be practiced without one or more of the specific features, details, components, materials, and/or methods of a particular embodiment or implementation. In other instances, additional features and advantages may be recognized in certain embodiments and/or implementations that may not be present in all embodiments or implementations. Further, in some instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the subject matter of the present disclosure. The features and advantages of the subject matter of the present disclosure will become more fully apparent from the following description and appended claims, or may be learned by the practice of the subject matter as set forth hereinafter.
In order that the advantages of the subject matter may be more readily understood, a more particular description of the subject matter briefly described above will be rendered by reference to specific embodiments that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the subject matter, they are not therefore to be considered to be limiting of its scope. The subject matter will be described and explained with additional specificity and detail through the use of the drawings, in which:
Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment. Similarly, the use of the term “implementation” means an implementation having a particular feature, structure, or characteristic described in connection with one or more embodiments of the present disclosure, however, absent an express correlation to indicate otherwise, an implementation may be associated with one or more embodiments.
The induction heating apparatus 104 includes one or more induction heating cells 106 each configured to generate eddy currents and provide heat in response to the eddy currents. In certain embodiments, each of the one or more induction heating cells 106 are attachably coupled together. In one embodiment, each induction heating cell of the one or more induction heating cells 106 is movable relative to adjacent induction heating cells of the one or more induction heating cells 106 to conform the one or more induction heating cells 106 to a non-planar surface. In various embodiments, each induction heating cell of the one or more induction heating cells 106 is individually controllable to provide induction heating. In some embodiments, each induction heating cell of the one or more induction heating cells 106 is controllable to a selected temperature, a selected power, and/or a selected frequency.
The induction heating apparatus 104 further includes a coupling device 108 that movably couples the one or more induction heating cells 106 together. The coupling device 108 may be any suitable device, such as one or more hinges, one or more wires, one or more cables, and so forth. In some implementations, the induction heating apparatus 104 includes a plurality of coupling devices 108 each movably coupling together one induction heating cell 106 to another adjacent induction heating cell 106.
The induction heating apparatus 104 additionally includes one or more power and/or data cables 110 that provide power and/or frequency to the one or more induction heating cells 106 and/or receive data from the one or more induction heating cells 106. The power and/or frequency is provided to the one or more induction heating cells 106 to cause the induction heating cells 106 to generate eddy currents in a metallic material, which provides heat to a part. Moreover, data may be received from the induction heating cells 106, such as temperature data, frequency data, and so forth.
The induction heating system 102 also includes a control system 112 that controls the one or more induction heating cells 106 to a desired temperature and/or frequency. In some embodiments, the control system 112 adjusts a voltage, current, and/or alternating frequency supplied to the one or more induction heating cells 106 to control the one or more induction heating cells 106 to a desired temperature and/or frequency.
In certain embodiments, the coupling features 602 may include apertures for inserting an object used to couple induction heating cells together. In the illustrated embodiment, the coupling features 602 include six apertures. The apertures may facilitate insertion of one or more hinges, wires, cables, etc. for coupling induction heating cells together.
As illustrated, the induction heating cell 106 may have a hexagonal shape, or any suitable shape, such as triangular, square, rectangular, octagonal, and so forth. As may be appreciated, the shape of the induction heating cell 106 may facilitate moving the induction heating cells of an array of induction heating cells relative to one another to conform the array of induction heating cells to a non-planar surface.
Additionally, the induction heating cell 106 includes an electrically conductive plate 702 (e.g., ferromagnetic plate) configured to be inserted into a lower side of the housing 700 such that the housing 700 covers at least a portion of the electrically conductive plate 702. While various embodiments describe the plate 702 as being electrically conductive, in some embodiments, the plate 702 may be manufactured from either conductive or non-conductive materials. The electrically conductive plate 702 includes an aperture 704 that may facilitate insertion of a thermocouple, a frequency detection device, and so forth. In some embodiments, the aperture 704 facilitates insertion of the electrically conductive plate 702 into the housing 700. The electrically conductive plate 702 also includes a circumferential groove 706 into which a coil 708 is disposed. The coil 708 includes a wire (e.g., an enameled magnet wire) that is wound around the electrically conductive plate 702 within the circumferential groove 706 to form a solenoid. The turns of the coil 708 generate a magnetic field when an AC current flows through the coil 708. The magnitude and frequency of the magnetic field is adjustable by adjusting the power and frequency of the AC current. The magnetic field generated by the coil 708 enters into the electrically conductive plate 702 and induces the formation of eddy currents within the electrically conductive plate 702. The eddy currents act to generate heat within the electrically conductive plate 702. Accordingly, in response to power and/or frequency being provided to the coil 708, the electrically conductive plate 702 is heated. The heat from the electrically conductive plate 702 can then be transferred, such as conduction or convection, to the part to heat the part. It should be noted that while the embodiment illustrated in
In some embodiments, the feedback reception device 902 receives temperature and/or frequency feedback from each induction heating cell of an array of induction heating cells (e.g., multiple induction heating cells coupled together). In certain embodiments, each induction heating cell of the array of induction heating cells is movable relative to adjacent induction heating cells of the array of induction heating cells to conform the array of induction heating cells to a non-planar surface.
In certain embodiments, the one or more induction generators 904 provide power and/or frequency to each induction heating cell of the array of induction heating cells. In various embodiments, the one or more induction generators are frequency matching induction generators that match a frequency corresponding to one or more induction heating cells of the array of induction heating cells, a material being heated, and/or a tool comprising the array of induction heating cells. In one embodiment, the controller 906 controls the one or more induction generators based on the temperature and/or frequency feedback.
Specifically, the induction generators 904 include induction generators 1002, 1004, 1006, 1008, 1010, and 1012. Moreover, the induction heating cells 106 include induction heating cells 1014, 1016, 1018, 1020, 1022, and 1024. The induction generator 1002 is directly coupled to the induction heating cell 1014 to provide the induction heating cell 1014 with a power signal having a frequency specific to the induction heating cell 1014. Further, the induction generator 1004 is directly coupled to the induction heating cell 1016 to provide the induction heating cell 1016 with a power signal having a frequency specific to the induction heating cell 1016. In addition, the induction generator 1006 is directly coupled to the induction heating cell 1018 to provide the induction heating cell 1018 with a power signal having a frequency specific to the induction heating cell 1018. Moreover, the induction generator 1008 is directly coupled to the induction heating cell 1020 to provide the induction heating cell 1020 with a power signal having a frequency specific to the induction heating cell 1020. Further, the induction generator 1010 is directly coupled to the induction heating cell 1022 to provide the induction heating cell 1022 with a power signal having a frequency specific to the induction heating cell 1022. In addition, the induction generator 1012 is directly coupled to the induction heating cell 1024 to provide the induction heating cell 1024 with a power signal having a frequency specific to the induction heating cell 1024.
As illustrated, the induction generator 904 includes induction generator 1102, and the induction heating cells 106 include induction heating cells 1104, 1106, 1108, 1110, 1112, and 1114. The induction generator 1102 is directly coupled to each of the induction heating cells 1104, 1106, 1108, 1110, 1112, and 1114.
As illustrated, the induction generator 904 includes induction generator 1202, and the induction heating cells 106 include induction heating cells 1204, 1206, 1208, 1210, 1212, and 1214. The induction generator 1202 is indirectly coupled to each of the induction heating cells 1204, 1206, 1208, 1210, 1212, and 1214. Each of the induction heating cells 1204, 1206, 1208, 1210, 1212, and 1214 is assigned a unique identifier. The induction generator 1202 assign unique identifiers to each specific power frequency output as a header packet as the frequencies are generated sequentially (e.g., in series) by the induction generator 1202. The unique identifier identifies the induction heating cell that a specific power frequency output is generated for and directed toward. A sequential signal 1216 is provided from the induction generator 1202 to a controller 1217. The controller 1217 uses the unique identifier located with each specific power frequency output to direct the power frequency output to the correct induction heating cell in the array. Moreover, as illustrated, each induction heating cell has a corresponding control module 1218, 1220, 1222, 1224, 1226, and 1228 positioned between the induction generator 1202 and the induction heating cells 1204, 1206, 1208, 1210, 1212, and 1214 to direct the specific power frequency outputs toward an induction heating cell identified by a respective unique identifier. Furthermore, the control modules 1218, 1220, 1222, 1224, 1226, and 1228 attach a unique identifier to returning frequency and/or power pulses that are directed back to the induction generator 1202.
The method 1400 includes receiving 1404 feedback from the one or more induction heating cells of the plurality of induction heating cells. The method 1400 also includes adjusting 1406 the power and/or frequency provided to the one or more induction heating cells of the plurality of induction heating cells in response to receiving the feedback from the one or more induction heating cells of the plurality of induction heating cells. In certain embodiments, adjusting 1406 the power and/or frequency provided to the one or more induction heating cells of the plurality of induction heating cells includes individually controlling the one or more induction heating cells of the plurality of induction heating cells to a selected temperature, a selected power, and/or a selected frequency.
In the above description, certain terms may be used such as “up,” “down,” “upper,” “lower,” “horizontal,” “vertical,” “left,” “right,” “over,” “under” and the like. These terms are used, where applicable, to provide some clarity of description when dealing with relative relationships. But, these terms are not intended to imply absolute relationships, positions, and/or orientations. For example, with respect to an object, an “upper” surface can become a “lower” surface simply by turning the object over. Nevertheless, it is still the same object. Further, the terms “including,” “comprising,” “having,” and variations thereof mean “including but not limited to” unless expressly specified otherwise. An enumerated listing of items does not imply that any or all of the items are mutually exclusive and/or mutually inclusive, unless expressly specified otherwise. The terms “a,” “an,” and “the” also refer to “one or more” unless expressly specified otherwise. Further, the term “plurality” can be defined as “at least two.”
Additionally, instances in this specification where one element is “coupled” to another element can include direct and indirect coupling. Direct coupling can be defined as one element coupled to and in some contact with another element. Indirect coupling can be defined as coupling between two elements not in direct contact with each other, but having one or more additional elements between the coupled elements. Further, as used herein, securing one element to another element can include direct securing and indirect securing. Additionally, as used herein, “adjacent” does not necessarily denote contact. For example, one element can be adjacent another element without being in contact with that element.
As used herein, the phrase “at least one of”, when used with a list of items, means different combinations of one or more of the listed items may be used and only one of the items in the list may be needed. The item may be a particular object, thing, or category. In other words, “at least one of” means any combination of items or number of items may be used from the list, but not all of the items in the list may be required. For example, “at least one of item A, item B, and item C” may mean item A; item A and item B; item B; item A, item B, and item C; or item B and item C. In some cases, “at least one of item A, item B, and item C” may mean, for example, without limitation, two of item A, one of item B, and ten of item C; four of item B and seven of item C; or some other suitable combination.
Unless otherwise indicated, the terms “first,” “second,” etc. are used herein merely as labels, and are not intended to impose ordinal, positional, or hierarchical requirements on the items to which these terms refer. Moreover, reference to, e.g., a “second” item does not require or preclude the existence of, e.g., a “first” or lower-numbered item, and/or, e.g., a “third” or higher-numbered item.
The schematic flow chart diagrams included herein are generally set forth as logical flow chart diagrams. As such, the depicted order and labeled steps are indicative of one embodiment of the presented method. Other steps and methods may be conceived that are equivalent in function, logic, or effect to one or more steps, or portions thereof, of the illustrated method. Additionally, the format and symbols employed are provided to explain the logical steps of the method and are understood not to limit the scope of the method. Although various arrow types and line types may be employed in the flow chart diagrams, they are understood not to limit the scope of the corresponding method. Indeed, some arrows or other connectors may be used to indicate only the logical flow of the method. For instance, an arrow may indicate a waiting or monitoring period of unspecified duration between enumerated steps of the depicted method. Additionally, the order in which a particular method occurs may or may not strictly adhere to the order of the corresponding steps shown.
Embodiments of the modules of the controller 112 may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, embodiments may take the form of a program product embodied in one or more computer readable storage devices storing machine readable code, computer readable code, and/or program code, referred hereafter as code. The storage devices may be tangible, non-transitory, and/or non-transmission. The storage devices may not embody signals. In a certain embodiment, the storage devices only employ signals for accessing code.
The modules of the controller 112 may be implemented as a hardware circuit comprising custom VLSI circuits or gate arrays, off-the-shelf semiconductors such as logic chips, transistors, or other discrete components. The modules of the controller 112 may also be implemented in programmable hardware devices such as field programmable gate arrays, programmable array logic, programmable logic devices or the like.
The modules of the controller 112 may also be implemented in code and/or software for execution by various types of processors. An identified module of code may, for instance, comprise one or more physical or logical blocks of executable code which may, for instance, be organized as an object, procedure, or function. Nevertheless, the executables of an identified module need not be physically located together, but may comprise disparate instructions stored in different locations which, when joined logically together, comprise the module and achieve the stated purpose for the module.
Indeed, a module of code may be a single instruction, or many instructions, and may even be distributed over several different code segments, among different programs, and across several memory devices. Similarly, operational data may be identified and illustrated herein within modules, and may be embodied in any suitable form and organized within any suitable type of data structure. The operational data may be collected as a single data set, or may be distributed over different locations including over different computer readable storage devices. Where a module or portions of a module are implemented in software, the software portions are stored on one or more computer readable storage devices.
Any combination of one or more computer readable medium may be utilized by the modules of the controller 112. The computer readable medium may be a computer readable storage medium. The computer readable storage medium may be a storage device storing the code. The storage device may be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, holographic, micromechanical, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing.
More specific examples (a non-exhaustive list) of the storage device would include the following: an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), a portable compact disc read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing. In the context of this document, a computer readable storage medium may be any tangible medium that can contain, or store a program for use by or in connection with an instruction execution system, apparatus, or device.
Code for carrying out operations for embodiments may be written in any combination of one or more programming languages including an object oriented programming language such as Python, Ruby, Java, Smalltalk, C++, or the like, and conventional procedural programming languages, such as the “C” programming language, or the like, and/or machine languages such as assembly languages. The code may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).
The present subject matter may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
| Number | Name | Date | Kind |
|---|---|---|---|
| 4595607 | Betteridge | Jun 1986 | A |
| 5113049 | Border et al. | May 1992 | A |
| 5378879 | Monovoukas | Jan 1995 | A |
| 6790206 | Panescu | Sep 2004 | B2 |
| 20080093356 | Pizzi | Apr 2008 | A1 |
| 20100282740 | Artigas Maestre | Nov 2010 | A1 |
| 20120074127 | Abbott | Mar 2012 | A1 |
| 20140151368 | Morrison | Jun 2014 | A1 |
| 20150219264 | Tailor | Aug 2015 | A1 |
| 20160353527 | Wang | Dec 2016 | A1 |
| Entry |
|---|
| Canadian Office Action concerning Canadian Patent Application No. 2,992,191 dated Feb. 9, 2021. |
| Number | Date | Country | |
|---|---|---|---|
| 20180279424 A1 | Sep 2018 | US |
