CN209861210U - Induction heating roller device - Google Patents
Induction heating roller device Download PDFInfo
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- CN209861210U CN209861210U CN201821830925.9U CN201821830925U CN209861210U CN 209861210 U CN209861210 U CN 209861210U CN 201821830925 U CN201821830925 U CN 201821830925U CN 209861210 U CN209861210 U CN 209861210U
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- secondary conductor
- main body
- roller
- roller main
- induction heating
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- 230000006698 induction Effects 0.000 title claims abstract description 84
- 238000010438 heat treatment Methods 0.000 title claims abstract description 56
- 239000004020 conductor Substances 0.000 claims abstract description 139
- 238000003466 welding Methods 0.000 claims abstract description 40
- 230000007246 mechanism Effects 0.000 claims abstract description 15
- 230000001939 inductive effect Effects 0.000 claims abstract 2
- 239000010949 copper Substances 0.000 claims description 37
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 31
- 229910052802 copper Inorganic materials 0.000 claims description 31
- 238000000034 method Methods 0.000 claims description 22
- 229910000881 Cu alloy Inorganic materials 0.000 claims description 21
- 230000002093 peripheral effect Effects 0.000 claims description 17
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 claims description 12
- 230000002265 prevention Effects 0.000 claims description 12
- 230000008569 process Effects 0.000 claims description 11
- 239000007788 liquid Substances 0.000 claims description 8
- 238000009751 slip forming Methods 0.000 claims description 4
- 238000004519 manufacturing process Methods 0.000 abstract description 2
- 229910052782 aluminium Inorganic materials 0.000 description 49
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 49
- 229910000906 Bronze Inorganic materials 0.000 description 33
- 239000010974 bronze Substances 0.000 description 33
- KUNSUQLRTQLHQQ-UHFFFAOYSA-N copper tin Chemical compound [Cu].[Sn] KUNSUQLRTQLHQQ-UHFFFAOYSA-N 0.000 description 33
- 238000012545 processing Methods 0.000 description 22
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 14
- 239000000463 material Substances 0.000 description 14
- 238000007747 plating Methods 0.000 description 11
- 229910000570 Cupronickel Inorganic materials 0.000 description 10
- 230000003647 oxidation Effects 0.000 description 9
- 238000007254 oxidation reaction Methods 0.000 description 9
- 230000020169 heat generation Effects 0.000 description 8
- 238000000151 deposition Methods 0.000 description 7
- 238000003754 machining Methods 0.000 description 7
- 229910052751 metal Inorganic materials 0.000 description 6
- 239000002184 metal Substances 0.000 description 6
- 230000001681 protective effect Effects 0.000 description 6
- 230000009471 action Effects 0.000 description 5
- 230000007797 corrosion Effects 0.000 description 5
- 238000005260 corrosion Methods 0.000 description 5
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- 238000010586 diagram Methods 0.000 description 5
- 230000000694 effects Effects 0.000 description 5
- 230000004907 flux Effects 0.000 description 5
- 229910052759 nickel Inorganic materials 0.000 description 5
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 4
- 230000015572 biosynthetic process Effects 0.000 description 4
- 238000005219 brazing Methods 0.000 description 4
- 239000010956 nickel silver Substances 0.000 description 4
- 238000012360 testing method Methods 0.000 description 4
- 238000004804 winding Methods 0.000 description 4
- 239000011701 zinc Substances 0.000 description 4
- 229910001020 Au alloy Inorganic materials 0.000 description 2
- 229910000990 Ni alloy Inorganic materials 0.000 description 2
- 229910001128 Sn alloy Inorganic materials 0.000 description 2
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 2
- 229910001297 Zn alloy Inorganic materials 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- 230000003247 decreasing effect Effects 0.000 description 2
- 230000004927 fusion Effects 0.000 description 2
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 2
- 239000010931 gold Substances 0.000 description 2
- 239000000696 magnetic material Substances 0.000 description 2
- 230000035515 penetration Effects 0.000 description 2
- 238000005096 rolling process Methods 0.000 description 2
- 238000007740 vapor deposition Methods 0.000 description 2
- 229910052725 zinc Inorganic materials 0.000 description 2
- 229910000975 Carbon steel Inorganic materials 0.000 description 1
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 description 1
- 239000011324 bead Substances 0.000 description 1
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- 238000005553 drilling Methods 0.000 description 1
- 230000005674 electromagnetic induction Effects 0.000 description 1
- 239000011888 foil Substances 0.000 description 1
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- 230000004048 modification Effects 0.000 description 1
- 239000004745 nonwoven fabric Substances 0.000 description 1
- 235000012149 noodles Nutrition 0.000 description 1
- 239000002985 plastic film Substances 0.000 description 1
- 229920006255 plastic film Polymers 0.000 description 1
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- 229910052709 silver Inorganic materials 0.000 description 1
- 239000004332 silver Substances 0.000 description 1
- 239000012209 synthetic fiber Substances 0.000 description 1
- 229920002994 synthetic fiber Polymers 0.000 description 1
Classifications
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Landscapes
- General Induction Heating (AREA)
- Rolls And Other Rotary Bodies (AREA)
Abstract
The utility model provides an induction heating roller device can reduce and be used for setting up the required manufacturing procedure of secondary conductor on the inboard is global of roller main part. The induction heating roller device (100) includes: a roller main body (2) rotatably supported; and an induction heating mechanism (3) which is provided inside the roller body (2), has an induction coil (32) for inducing the roller body (2) to generate heat, and has a secondary conductor (4) formed on the inner circumferential surface (201a) of the roller body (2) by build-up welding.
Description
Technical Field
The utility model relates to an induction heating roller device, in particular to roller main part with secondary conductor.
Background
The induction heating roll device includes a roll main body made of a magnetic material and an induction heating mechanism provided in the roll main body and having an induction coil, and the roll main body is inductively heated by applying a commercial ac voltage to the induction coil. In the induction heating roller device, the roller main body constitutes both a magnetic circuit through which magnetic flux passes and a current circuit through which short-circuit current flows due to electromagnetic induction. Therefore, the roller main body generates resistance that makes it difficult for short-circuit current to flow, and the power factor is reduced.
As a method for preventing the power factor from being lowered, as shown in patent document 1, it is conceivable to provide a secondary conductor made of a nonmagnetic material on the inner circumferential surface of the roller main body.
Conventionally, as a method of providing a secondary conductor on the inner circumferential surface of a roller main body, there is the following method.
First, a copper plate is bent and then joined by silver brazing or the like to form a cylindrical pipe body. And performing plating treatment for rust prevention on the pipe body. Then, the tube body after the plating treatment is brazed to the inner peripheral surface of the roller main body. Thereby, the secondary conductor is disposed on the inner peripheral surface of the roller main body. In addition to brazing, there is also a method of performing setting by press-fitting the pipe body into a roller main body or by heat-fitting the pipe body to the roller main body.
However, according to the above method, a plurality of processing steps such as a step of producing a pipe body from a copper plate, a step of plating the pipe body for rust prevention, and a step of mounting the pipe body to a roller main body are required.
Further, the method of mounting by brazing is difficult to perform brazing over the entire outer peripheral surface of the pipe body, and therefore, is not suitable for a roller body rotating at high speed in some cases. In the mounting method such as press fitting or shrink fitting, the roller main body and the secondary conductor are mechanically brought into close contact with each other, and the roller main body and the secondary conductor are loosened by repetition of temperature change due to a difference in thermal expansion between the roller main body and the secondary conductor. As a result, there is a problem that the thermal conductivity between the roller main body and the secondary conductor is reduced.
Documents of the prior art
Patent document 1: japanese Utility model gazette Sho 45-29650
SUMMERY OF THE UTILITY MODEL
The utility model discloses a be used for solving problem point and the utility model made, the main objective of the utility model is to reduce and be used for setting up the required manufacturing procedure of secondary conductor on the inboard of roller main part is global.
Namely, the utility model discloses an induction heating roller device, it includes: a roller main body rotatably supported; and an induction heating mechanism provided inside the roller main body and having an induction coil for causing the roller main body to generate heat by induction, the roller main body being caused to generate heat by induction by applying an alternating voltage of a power frequency to the induction coil, a secondary conductor being formed on an inner peripheral surface of the roller main body by build-up welding, the secondary conductor being composed of aluminum bronze, and the surface of the secondary conductor being not subjected to rust-proof treatment.
According to such an induction heating roller device, since the secondary conductor is formed by build-up welding, a conventional pipe body forming process and a pipe body mounting process can be omitted. Further, since a thin protective oxide film is formed on the surface of the aluminum bronze, the aluminum bronze has a property of preventing high-temperature oxidation, and is corrosion-resistant. By using the aluminum bronze for the secondary conductor, a rust prevention treatment process such as a plating process can be omitted. As a result, the number of processing steps required for providing the secondary conductor on the inner circumferential surface of the roller main body can be reduced. Further, the work of attaching the secondary conductor to the inner circumferential surface of the roller main body can be easily performed only by overlay welding. Further, since the secondary conductor is formed by overlay welding, the roller main body and the secondary conductor are integrated, and thus the roller main body and the secondary conductor can be applied to high-speed rotation, and there is no slack due to a difference in thermal expansion coefficient between the roller main body and the secondary conductor, and a decrease in thermal conductivity between the roller main body and the secondary conductor can be suppressed.
Here, the resistance value of aluminum bronze is about 6 times larger than that of copper, and a thickness of about 6 times is required to obtain an effect equivalent to that of copper. However, since the current penetration depth of aluminum bronze in induction heating at commercial frequency is calculated to be as deep as about 22mm (20 ℃ C., 60Hz), the necessary thickness can be set to be equal to or less than the current penetration thickness. The required thickness is a thickness for obtaining a target power factor (for example, 80% or more), and can be calculated using an equivalent circuit diagram (see fig. 4) in induction heating at the power frequency.
Although the greater the aluminum content of the aluminum bronze, the stronger the protective properties of the oxide, the oxidation resistance was not much improved even when 6% or more of aluminum was added (see fig. 5). Therefore, it is preferable that the aluminum bronze contains 6% or more of aluminum.
The induction heating roller device further includes: a power supply unit configured to supply power to the induction heating mechanism; and a temperature control unit for controlling the temperature of the roller body by controlling the power supply unit, and controlling the temperature of the roller body to a predetermined value by the temperature control unit.
Aluminum bronzes containing 6% or more of aluminum have a problem that oxidation is extremely slight at 500 ℃ or lower, but if the temperature is increased to a high level higher than 500 ℃, the weight increases due to oxidation (see fig. 6). Therefore, it is preferable that the settable temperature of the temperature control portion is 500 ℃ or lower.
Therefore, it is preferable that the induction heating roller device further includes: a power supply unit configured to supply power to the induction heating mechanism; and a temperature control unit for controlling the temperature of the roller main body by controlling the power supply unit, wherein the temperature control unit has a possible temperature setting of 500 ℃ or lower.
The aluminum bronze surface welded by the bead welding causes slight thickness unevenness in the circumferential direction, particularly in the width direction. However, if the weight of the aluminum bronze to be welded is controlled, the average thickness of the winding width of the induction coil can be calculated. As a result, the power and the power factor can be made in accordance with the design values.
Further, if a jacket chamber in which a heat medium of vapor-liquid two-phase (vapor-liquid two-phase) is depressurized is formed in the wall of the roll main body, even if uneven heat generation occurs due to uneven thickness of the aluminum bronze, the surface temperature of the roll main body can be made uniform by the temperature equalizing action of the jacket chamber. Therefore, machining for making the thickness of the secondary conductor uniform is not required. That is, it is not necessary to perform planarization processing by removal processing on the surface of the secondary conductor.
Therefore, it is preferable that a jacket chamber is formed in a wall of the roller main body, a vapor-liquid two-phase heat medium is sealed in the jacket chamber under reduced pressure, and the surface of the secondary conductor is not subjected to planarization by a removal process.
The jacket chamber in the wall of the roller body is formed by drilling from the end surface of the roller body in the axial direction to form a bore in the wall of the roller body and close the opening of the bore. Here, since the axial dimension of the roller body is long, the bore hole does not advance straight and is bent. When the thickness of the roll body is small, the drill may penetrate the surface or inner circumferential surface of the roll body, and the roll body may have to be reworked. In order to improve the life, the surface of the roller body may be subjected to hardening treatment such as induction hardening, and in this case, the bore is not bent in the surface direction but is bent toward the inner peripheral surface side.
However, when the secondary conductor is deposited on the inner circumferential surface of the roller body, the structure thereof is, from the outside, a weld metal, a fused portion, a heat affected portion, and a base material portion. The fusion part is a boundary line between the weld metal and the base material, and a heat affected part is formed by several mm close to the base material side of the fusion part. If the arc passes through, the temperature of the heat affected zone, which becomes high temperature due to the welding heat, starts to drop rapidly and is cooled rapidly, and the heat is rapidly cooled to a structure different from the original base material by the heating, resulting in an increase in hardness. In the case of overlaying aluminum bronze, since the hardness of the inner circumferential surface of the roller body is increased, the bore is less likely to bend toward the inner circumferential surface, and the disadvantage that the bore penetrates the inner circumferential surface of the roller body can be reduced.
Since the magnetic flux generated by the induction coil is concentrated toward the center of the coil in induction heating, the temperature of the roller main body tends to increase at the center in the axial direction of the roller main body. On the other hand, the portion where the secondary conductor is thickly deposited has low resistance, and therefore a large current flows, resulting in a large amount of heat generation. Therefore, if the portion corresponding to the end of the winding width of the induction coil is subjected to build-up welding, the amount of heat generated by the roller main body can be made uniform in the axial direction. Further, by adjusting the thickness of the build-up welding, the amount of heat generation of the roller main body can be locally increased or decreased. Therefore, it is preferable that the thickness of the secondary conductor varies in the axial direction of the roller main body.
Preferably, the secondary conductor is formed in a ring shape at intervals on an inner circumferential surface of the roller main body. By forming the secondary conductors at such intervals, the processing can be facilitated.
In particular, in order to facilitate the processing of the secondary conductor and to enable continuous processing of the secondary conductor, it is preferable that the secondary conductor is formed in a spiral shape with a gap in the inner circumferential surface of the roller main body.
In order to make the electrical characteristics of the respective induction heating roller devices the same, it is preferable that the electrical characteristics of the induction heating roller devices are adjusted according to the weight of the secondary conductor. For example, if the specifications of the roller bodies are the same, the power factor and the power are also the same by making the weights of the processed secondary conductors the same, and the work management is extremely easy.
Furthermore, the utility model discloses an induction heating roller device, it includes: a roller main body rotatably supported; and an induction heating mechanism which is provided inside the roller main body, has an induction coil for induction heating of the roller main body, and is caused to inductively heat the roller main body by applying an alternating current voltage of a commercial frequency to the induction coil, wherein a secondary conductor is formed on an inner peripheral surface of the roller main body by build-up welding, the secondary conductor is composed of cupronickel (cupro-nickel, an alloy of copper and nickel), german silver (cupronickel, an alloy of copper and zinc and nickel), red copper (an alloy of copper and gold), gunning copper (a alloy of copper and tin), or a combination thereof, and a surface of the secondary conductor is not subjected to rust-preventive treatment. Cupronickel (cupro-nickel), german silver (zinc cupronickel), cupronickel (red copper), and gunmetal (gun copper) are also non-magnetic copper alloys having high corrosion resistance. By using them for the secondary conductor, the same effect as when aluminum bronze is used can be obtained.
The secondary conductor formed by the build-up welding may have a thickness variation in the circumferential direction, particularly in the width direction. The uneven thickness causes uneven heat generation. Therefore, conventionally, in order to make the thickness of the secondary conductor uniform, it is necessary to perform machining (planarization) on the surface of the secondary conductor. In addition, considering the planarization process for the secondary conductor, the secondary conductor is formed to be thick and then removed by machining, which requires an additional material.
In order to solve the problem well, the utility model discloses an induction heating roller device, it includes: a roller main body rotatably supported; and an induction heating mechanism provided inside the roller main body and having an induction coil for causing the roller main body to generate heat by induction, the roller main body being caused to generate heat by induction by applying an alternating-current voltage of a power frequency to the induction coil, a jacket chamber being formed in a wall of the roller main body, a vapor-liquid two-phase heat medium being sealed in the jacket chamber by pressure reduction, a secondary conductor being formed on an inner peripheral surface of the roller main body by build-up welding, the secondary conductor being composed of copper or a copper alloy, and a surface of the secondary conductor not being subjected to planarization treatment by removal processing.
Because the utility model discloses a build-up welding forms secondary conductor, so can omit body formation process and body installation process in the past. As a result, the number of processing steps required for providing the secondary conductor on the inner circumferential surface of the roller main body can be reduced. Further, the work of attaching the secondary conductor to the inner circumferential surface of the roller main body can be easily performed only by overlay welding. Further, since the secondary conductor is formed by overlay welding, the roller main body and the secondary conductor are integrated, and thus the roller main body and the secondary conductor can be applied to high-speed rotation, and there is no slack due to a difference in thermal expansion coefficient between the roller main body and the secondary conductor, and a decrease in thermal conductivity between the roller main body and the secondary conductor can be suppressed.
The copper or copper alloy subjected to the build-up welding has slight thickness unevenness in the circumferential direction, particularly in the width direction. However, if the weight of the copper or copper alloy to be welded is controlled, the average thickness of the winding width of the induction coil can be calculated. As a result, the power and the power factor can be generated in accordance with the calculated values.
Further, if a jacket chamber in which a vapor-liquid two-phase heat medium is sealed under reduced pressure is formed in the wall of the roll main body, even if uneven heat generation occurs due to uneven thickness of copper or copper alloy, the surface temperature of the roll main body can be made uniform by the temperature equalizing action of the jacket chamber. Therefore, machining for making the thickness of the secondary conductor uniform is not required. That is, it is not necessary to perform planarization processing by removal processing on the surface of the secondary conductor. As a result, the processing of the secondary conductor can be reduced, and no additional material is required because the secondary conductor is not removed.
In order to further improve the power factor of the induction heating roller device, it is preferable that the secondary conductor has a cylindrical shape continuously formed from one end portion to the other end portion in the axial direction of the roller main body.
When copper is heated to a high temperature, oxidation proceeds to form an oxide, which changes the electrical characteristics and also changes the induction heating characteristics. In addition, oxidation tends to be more severe at high temperatures among various copper alloys. Therefore, the surface of the secondary conductor is preferably subjected to rust prevention treatment.
As the rust-proof treatment, it is preferable to form a film using metal or ceramic which can withstand the temperature of the roller body to be used and is less likely to be oxidized at the temperature. For example, if nickel plating is performed, it can be used up to about 400 ℃, and if aluminum deposition is performed, it can be used up to about 500 ℃ due to aluminum being oxidized and aluminized at high temperature.
According to the present invention configured as described above, the number of processing steps required for providing the secondary conductor on the inner peripheral surface of the roller main body can be reduced.
Drawings
Fig. 1 is a diagram schematically showing the structure of an induction heating roller device according to the present embodiment.
Fig. 2 is a cross-sectional view schematically showing a formation method of a secondary conductor according to the same embodiment.
Fig. 3 is a schematic view showing a method of forming a secondary conductor according to the same embodiment.
Fig. 4 is an equivalent circuit diagram of the induction heating roller device.
FIG. 5 is a graph showing the relationship between the amount of oxide increase in each aluminum content of aluminum bronze and elapsed time.
FIG. 6 is a graph showing the relationship between the amount of increase in oxide in each aluminum content of aluminum bronze and temperature.
Fig. 7 is a cross-sectional view schematically showing a formation method of the secondary conductor according to the modified embodiment.
Fig. 8 is a cross-sectional view schematically showing a formation method of the secondary conductor according to the modified embodiment.
Description of the reference numerals
100 induction heating roller device
2 roller body
201a inner peripheral surface
3 Induction heating mechanism
32 induction coil
4 secondary conductor
Detailed Description
An embodiment of an induction heating roller device according to the present invention will be described below with reference to the drawings.
The induction heating roller device 100 of the present embodiment is used in, for example, a continuous heat treatment process of sheet materials such as plastic films, papers, cloths, nonwoven fabrics, synthetic fibers, and metal foils, woven materials, and continuous materials such as thread (wire) materials.
<1. device Structure >
Specifically, as shown in fig. 1, the induction heating roller apparatus 100 includes: a hollow cylindrical roller body 2 rotatably supported; and an induction heating mechanism 3 provided inside the roller main body 2.
Hollow drive shafts 21 are provided at both ends of the roller body 2, and the drive shafts 21 are rotatably supported by the machine base 9 via bearings 8 such as rolling bearings. The drive shaft 21 has a flange 211 (see fig. 2) connected to an axial end surface of the roller body 2. The roller main body 2 including the drive shaft 21 is formed of a magnetic material such as carbon steel. The roller main body 2 is rotated by a driving force applied from the outside by a rotation driving mechanism (not shown) such as a motor. Further, a jacket chamber 2A is formed in a side peripheral wall 201 which is a wall portion of the roller main body 2 of the present embodiment, and a vapor-liquid two-phase heat medium is sealed in the jacket chamber 2A under reduced pressure. The jacket chamber 2A extends in the longitudinal direction (the rotational axis direction) in the side peripheral wall 201, and is formed in plurality at equal intervals in the circumferential direction.
The induction heating mechanism 3 includes a cylindrical core 31 having a cylindrical shape and an induction coil 32 wound around an outer circumferential surface of the cylindrical core 31.
Support shafts 33 are provided at both ends of the cylindrical core 31, and the support shafts 33 are inserted into the drive shaft 21, respectively, and rotatably supported by the drive shaft 21 via bearings 10 such as rolling bearings. Thereby, the induction heating mechanism 3 is kept in a stationary state with respect to the frame 9 (fixed side) inside the rotating roller main body 2.
Further, an external lead L1 is connected to the induction coil 32, and a power supply device 5 for applying an ac voltage of a commercial frequency (50Hz or 60Hz) is connected to the external lead L1, the power supply device 5 being provided. The power supply device 5 includes: a power supply unit 51 for supplying an alternating current to the induction heating mechanism 3; and a temperature control unit 52 for controlling the temperature of the roller body 2 by controlling the power supply unit 51. The temperature control unit 52 is a dedicated or general-purpose computer having a CPU, an internal memory, an input/output interface, an AD converter, and the like, and controls the power supply unit 51 based on a set temperature signal input from a user so as to control the surface temperature of the roller body 2 to be the set temperature. The temperature control unit 52 may be an analog circuit.
With such an induction heating mechanism 3, if an alternating voltage is applied to the induction coil 32, an alternating magnetic flux is generated, and the alternating magnetic flux passes through the side peripheral wall 201 of the roller main body 2. An induced current is generated in the roller main body 2 due to the passage of the magnetic flux, and the roller main body 2 generates joule heat due to the induced current. Further, the temperature distribution in the rotational axis direction of the side peripheral wall 201 of the roller main body 2 is uniformly distributed by the jacket chamber 2A.
However, the secondary conductor 4 is formed on the inner circumferential surface of the roller body 2 of the present embodiment by build-up welding. Here, the material (weld deposit material) of the secondary conductor 4 is aluminum bronze (an alloy of aluminum and copper). The aluminum bronze of the present embodiment contains 6% or more of aluminum.
Specifically, the secondary conductor 4 is formed integrally in the circumferential direction on the inner circumferential surface 201a of the roller body 2, and is formed continuously in the rotational axis direction of the roller body 2.
Here, the secondary conductor 4 is formed in a spiral shape (spiral), and the welding portions adjacent to each other are formed so as to be continuous while being in contact with each other. That is, the secondary conductor 4 is continuously formed over the entire winding width of the induction coil 32 in the rotational axis direction of the roller body 2. In other words, the secondary conductor 4 has a cylindrical shape formed along the rotational axis direction of the roller main body 2. Further, a protective oxide film is formed on the surface of the secondary conductor 4 formed of the aluminum bronze having the above-described configuration. The secondary conductor 4 has an antirust function by the protective oxide film.
Next, an example of a build-up welding operation for forming the secondary conductor 4 on the inner circumferential surface 201a of the roller body 2 will be described with reference to fig. 3.
The roller body 2 is attached to a turning device 11 that turns the roller body 2. A welding torch 12 is inserted into the roller main body 2 in this state, and the welding torch 12 is relatively moved in the rotational axis direction with respect to the roller main body 2 by rotating the roller main body 2 by the rotating device 11, whereby a secondary conductor 4 having a spiral shape is formed on the inner circumferential surface 201a of the roller main body 2. In the overlay welding, various types of secondary conductors 4 can be formed by appropriately setting welding conditions such as pre-welding conditions such as preheating of the roller main body 2, the size and material of the welding wire, the torch angle, the torch position, the voltage, the current, the rotational speed of the roller main body 2, the moving speed of the welding torch 12 (overlay welding pitch), and post-welding conditions such as post-heating of the roller main body 2.
Since the protective oxide film is formed on the surface of the secondary conductor 4 configured as described above, it is not necessary to perform plating for rust prevention, and the plating is not performed in the present embodiment.
Further, since the jacket chamber 2A is formed in the side peripheral wall 201 of the roller main body 2, even if uneven heat generation occurs due to uneven thickness of the aluminum bronze, the surface temperature of the roller main body 2 can be made uniform by the temperature equalizing action of the jacket chamber 2A. Therefore, in the present embodiment, machining for making the thickness of the secondary conductor 4 uniform is not required. That is, the surface of the secondary conductor 4 is not subjected to the planarization treatment by the removal processing for removing the convex portion.
In the induction heating roller device 100, the temperature control unit 52 may set the temperature to 500 ℃. I.e. the user cannot set a temperature of more than 500 c. This is because: the aluminum bronze containing 6% or more of aluminum has extremely slight oxidation at 500 ℃ or less, but if it is heated to a high temperature higher than 500 ℃, there is a problem that weight increases due to oxidation.
Next, the results of the power factor test of the induction heating roller device are shown. The roller body used in this test had a diameter of 237mm, a surface length of 400mm and a wall thickness of 22 mm. Further, 30 jacket chambers having a diameter of 10mm and a length of 380mm were disposed at equal intervals at the center of the roll main body having a wall thickness of 22 mm. The axial width of the secondary conductor is 380 mm. The electrical specification is: the input was a single phase 60Hz220V and the power was 5kW without secondary conductors.
Table 1 below shows the power factor in the case where no overlay welding was performed, the case where copper was applied (overlay welding thickness of 0.5mm, 1.0mm, 1.5mm), and the case where aluminum bronze containing 8% aluminum was applied (overlay welding thickness of 1.5mm, 3.0mm), respectively. The thickness (mm) of the weld deposit is an average value in the axial direction.
[ Table 1]
| Kind of metal to be deposited | Build-up thickness (mm) | Power factor (%) |
| Is free of | 0 | 70.2 |
| Copper (Cu) | 0.5 | 87.4 |
| Copper (Cu) | 1.0 | 89.7 |
| Copper (Cu) | 1.5 | 91.2 |
| 8% aluminum bronze | 1.5 | 83.5 |
| 8% aluminum bronze | 3.0 | 88.4 |
As is clear from table 1, when the secondary conductor 4 is formed by depositing aluminum bronze and the deposition thickness of 8% aluminum bronze is 1.5mm or more, the power factor is improved and becomes the target power factor (80%) or more, as compared with the case where deposition is not performed. It is also considered that the same effect can be obtained even with 6% aluminum bronze. Further, by using an equivalent circuit diagram of commercial frequency induction heating, a build-up thickness equal to or larger than a target power factor (80%) can be calculated.
<2 > effects of the present embodiment
According to the induction heating roller device 100 configured as described above, since the secondary conductor 4 is formed by build-up welding, the conventional pipe body forming step and pipe body mounting step can be omitted. Further, since a thin protective oxide film is formed on the surface of the aluminum bronze, the aluminum bronze has a property of preventing oxidation at high temperatures, and the corrosion resistance is enhanced. By using the aluminum bronze as the secondary conductor 4, a rust prevention treatment process such as a plating process can be omitted. As a result, the number of processing steps required for providing the secondary conductor 4 on the inner circumferential surface 201a of the roller body 2 can be reduced. Further, the work of attaching the secondary conductor 4 to the inner circumferential surface of the roller body 2 can be easily performed only by overlay welding. Further, since the secondary conductor 4 is formed by overlay welding, the roller body 2 and the secondary conductor 4 are integrated, and thus the roller body is applicable to high-speed rotation, and there is no slack due to a difference in thermal expansion coefficient between the roller body 2 and the secondary conductor 4, and a decrease in thermal conductivity between the roller body 2 and the secondary conductor 4 can be suppressed.
<3 > a modified embodiment of the present invention
In addition, the present invention is not limited to the above embodiment.
The secondary conductor of the above embodiment may be made of copper or a copper alloy. As the copper alloy, for example, a nonmagnetic copper alloy having high corrosion resistance, aluminum bronze (an alloy of aluminum and copper), cupro-nickel (an alloy of copper and nickel), german silver (zinc cupro, an alloy of copper and zinc and nickel), red copper (an alloy of copper and gold), gunmetal (an alloy of copper and tin), or a combination thereof can be considered. Further, the surface of the secondary conductor 4 is subjected to rust prevention treatment. Examples of the rust-proofing treatment include plating such as nickel plating and vapor deposition such as aluminum vapor deposition. The rust prevention treatment is performed after the secondary conductor 4 is formed in the same manner as in the above embodiment.
Further, as in the foregoing embodiment, since the jacket chamber 2A is formed in the side peripheral wall 201 of the roller main body 2, even if the unevenness in heat generation occurs due to the unevenness in thickness of copper or a copper alloy, the surface temperature of the roller main body 2 can be made uniform by the temperature equalizing action of the jacket chamber 2A. Therefore, machining for making the thickness of the secondary conductor 4 uniform is not required. That is, the surface of the secondary conductor 4 is not subjected to the planarization treatment by the removal processing for removing the convex portion.
Next, the results of the power factor test of the induction heating roller device are shown. The roller body used in this test had a diameter of 237mm, a surface length of 400mm and a wall thickness of 22 mm. Further, 30 jacket chambers having a diameter of 10mm and a length of 380mm were disposed at equal intervals at the center of the roll main body having a wall thickness of 22 mm. The axial width of the secondary conductor is 380 mm. The electrical specification is: the input single phase is 60Hz220V and the power is 5kW without secondary conductors.
Table 2 below shows the power factors of the case where no overlay welding was performed and the case where copper was deposited (the thickness of the overlay welding was 0.5mm, 1.0mm, and 1.5 mm). The thickness (mm) of the weld deposit is an average value in the axial direction.
[ Table 2]
| Kind of metal to be deposited | Build-up thickness (mm) | Power factor (%) |
| Is free of | 0 | 70.2 |
| Copper (Cu) | 0.5 | 87.4 |
| Copper (Cu) | 1.0 | 89.7 |
| Copper (Cu) | 1.5 | 91.2 |
As is clear from table 2, when the secondary conductor 4 is formed by depositing copper, the power factor is improved and becomes equal to or higher than the set target power factor (80%) as compared with the case where deposition is not performed. Further, by using an equivalent circuit diagram of commercial frequency induction heating, a build-up thickness equal to or larger than a target power factor (80%) can be calculated.
In the induction heating roller device 100, the temperature control unit 52 may be set to a temperature of, for example, 500 ℃. I.e. the user is not allowed to set a temperature of more than 500 c. The settable temperature is determined according to the type of rust prevention treatment performed on the surface of the secondary conductor 4. For example, if the rust prevention treatment is nickel plating, the possible temperature is set to 400 ℃ or lower, and if the rust prevention treatment is aluminum deposition, the possible temperature is set to 500 ℃ or lower.
Even in the induction heating roller apparatus 100 configured as described above, the secondary conductor 4 is formed by build-up welding, so that the conventional pipe body forming step and pipe body mounting step can be omitted. As a result, the number of processing steps required for providing the secondary conductor 4 on the inner circumferential surface 201a of the roller body 2 can be reduced. Further, the work of attaching the secondary conductor 4 to the inner circumferential surface 201a of the roller body 2 can be easily performed only by build-up welding. Further, since the secondary conductor 4 is formed by overlay welding, the roller body 2 and the secondary conductor 4 are integrated, and thus the roller body is applicable to high-speed rotation, and there is no slack due to a difference in thermal expansion coefficient between the roller body 2 and the secondary conductor 4, and a decrease in thermal conductivity between the roller body 2 and the secondary conductor 4 can be suppressed.
Further, if the jacket chamber 2A in which the heat medium of vapor-liquid two phases is sealed under reduced pressure is formed in the wall of the roll main body 2, the surface temperature of the roll main body 2 can be made uniform by the temperature equalizing action of the jacket chamber 2A even if the unevenness in heat generation occurs due to the unevenness in thickness of copper or copper alloy. Therefore, machining for making the thickness of the secondary conductor 4 uniform is not required. That is, it is not necessary to perform planarization processing using removal processing on the surface of the secondary conductor 4. As a result, the processing of the secondary conductor 4 can be reduced, and no additional material is required because the secondary conductor 4 is not removed.
The secondary conductor 4 can be adjusted in thickness in the direction of the rotational axis of the roller body 2. That is, the thickness of the secondary conductor 4 can be varied in the direction of the rotational axis of the roller body 2. With this configuration, the amount of heat generated by the roller main body 2 can be locally increased or decreased.
Further, the secondary conductor of the embodiment uses aluminum bronze, but cupronickel, german silver, cupronickel, gunmetal, or a combination thereof may also be used. These are all nonmagnetic copper alloys having high corrosion resistance, and can obtain the same effect as aluminum bronze.
Further, the secondary conductor may be formed in an annular shape on the inner circumferential surface of the roller main body, and a plurality of secondary conductors may be continuously formed in the rotational axis direction of the roller main body.
Further, the plurality of secondary conductors may be intermittently formed in the rotational axis direction of the roller main body. For example, as shown in fig. 7, the secondary conductor 4 may be formed in a ring shape at intervals on the inner circumferential surface 201a of the roller body 2, or as shown in fig. 8, the secondary conductor 4 may be formed in a spiral shape at intervals on the inner circumferential surface 201a of the roller body 2. By forming the secondary conductor 4 at such intervals, the processing can be made easier than the processing of continuously forming. Further, as shown in fig. 8, the secondary conductor 4 can be continuously processed by forming a spiral shape.
In addition, the electrical characteristics of the induction heating roller device can be adjusted according to the weight of the secondary conductor. For example, if the specifications of the roller bodies are the same, the power factor and the power can be made the same by making the weights of the processed secondary conductors the same, and the work management is extremely easy. The following table shows the electrical characteristics when the weights of the secondary conductors are the same, and it is understood that the electrical characteristics are substantially the same as long as the weights of the secondary conductors are the same. In addition, the following dimensions of the roller body are: 300mm in diameter, 280mm in internal diameter and 189mm in face length, the secondary conductor is pure copper and weighs about 800 g. The case of using pure copper as the secondary conductor is shown, but the same is true of using aluminum bronze.
[ Table 3]
| Secondary conductor shape | Voltage (V) | Current (A) | Power (kW) | Power factor (%) |
| Is free of | 418.0 | 74.5 | 14.1 | 45.2 |
| In the form of a ring | 419.7 | 86.7 | 21.7 | 59.6 |
| Helical shape | 420.3 | 87.3 | 22.3 | 60.7 |
| Whole noodles | 419.5 | 86.8 | 22.1 | 60.8 |
The present invention is not limited to the above embodiment, and various modifications may be made without departing from the scope of the present invention.
The technical features described in the embodiments (examples) of the present invention can be combined with each other to form a new technical solution.
Claims (7)
1. An induction heat generating roller device, comprising: a roller main body rotatably supported; and an induction heating mechanism which is provided inside the roller main body, has an induction coil for inducing the roller main body to generate heat, and induces the roller main body to generate heat by applying a commercial frequency AC voltage to the induction coil,
the induction heating roller device is characterized in that,
a jacket chamber in which a vapor-liquid two-phase heat medium is sealed under reduced pressure is formed in a wall of the roller main body,
a secondary conductor is formed on the inner circumferential surface of the roller main body by build-up welding,
the secondary conductor is composed of copper or a copper alloy,
the surface of the secondary conductor is not subjected to planarization treatment using a removal process.
2. The induction heat generating roller device according to claim 1, wherein the secondary conductor has a cylindrical shape continuously formed from one end portion to the other end portion in the axial direction of the roller main body.
3. The induction heat generating roller device according to claim 1, wherein a surface of the secondary conductor is subjected to rust prevention treatment.
4. An induction heat generating roller device according to claim 1, wherein the thickness of said secondary conductor varies in the axial direction of said roller main body.
5. The induction heating roller device according to claim 1, wherein the secondary conductor is formed in a ring shape at intervals on an inner peripheral surface of the roller main body.
6. The induction heating roller device according to claim 1, wherein the secondary conductor is formed in a spiral shape at intervals on an inner peripheral surface of the roller main body.
7. An induction heat generating roller apparatus according to claim 1, wherein an electrical characteristic of the induction heat generating roller apparatus is adjusted according to a weight of the secondary conductor.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2017218451 | 2017-11-13 | ||
| JP2017-218451 | 2017-11-13 | ||
| JP2018-155995 | 2018-08-23 | ||
| JP2018155995A JP7261438B2 (en) | 2017-11-13 | 2018-08-23 | Induction heating roller device |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN209861210U true CN209861210U (en) | 2019-12-27 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201821830925.9U Expired - Fee Related CN209861210U (en) | 2017-11-13 | 2018-11-07 | Induction heating roller device |
Country Status (3)
| Country | Link |
|---|---|
| JP (1) | JP7261438B2 (en) |
| CN (1) | CN209861210U (en) |
| TW (1) | TW201924483A (en) |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS4529649Y1 (en) * | 1965-11-27 | 1970-11-13 | ||
| JP2003223063A (en) * | 2002-01-30 | 2003-08-08 | Matsushita Electric Ind Co Ltd | Fixation device |
| JP2010094807A (en) * | 2008-09-19 | 2010-04-30 | Think Laboratory Co Ltd | Heating roller with recessed part |
| CN102474915A (en) * | 2009-07-31 | 2012-05-23 | 新智德株式会社 | Electromagnetic induction heating element and fixing belt |
| WO2012111711A1 (en) * | 2011-02-15 | 2012-08-23 | 株式会社村田製作所 | Multilayered wired substrate and method for producing the same |
| JP6103964B2 (en) * | 2013-02-04 | 2017-03-29 | 中国塗料株式会社 | Two-component primer, primer coating, laminated antifouling coating and substrate antifouling method |
| JP6765166B2 (en) * | 2014-09-16 | 2020-10-07 | トクデン株式会社 | Induction heating roller device |
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2018
- 2018-08-23 JP JP2018155995A patent/JP7261438B2/en active Active
- 2018-11-07 CN CN201821830925.9U patent/CN209861210U/en not_active Expired - Fee Related
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| JP2019091681A (en) | 2019-06-13 |
| TW201924483A (en) | 2019-06-16 |
| JP7261438B2 (en) | 2023-04-20 |
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