JP3907076B2 - Induction heating device and method of manufacturing heating coil mounting unit used in induction heating device - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an induction heating device and a method for manufacturing a heating coil mounting unit used in the induction heating device, and more particularly to an improvement of a heating coil mounting unit including a heating coil.
[0002]
[Prior art]
For example, when heating steel frames, steel pipes, pressure vessels, etc. for the purpose of preheating and postheating related to welding work and gas cutting work, various heat treatments such as post-welding heat treatment, and distortion correction, etc. High frequency induction heating devices or low frequency induction heating devices are widely used.
[0003]
As is well known, the induction heating device applies a current to a heating coil mounted on a steel pipe or the like and heats the steel pipe or the like using heat generated by electromagnetic induction. The heating coil is attached to a heated object such as a steel pipe through a heat insulating material in order to prevent burning and heat loss due to radiant heat from the steel pipe or the like. .
[0004]
Here, when heating an object to be heated such as a steel pipe by an induction heating device, first, a heat insulating material is applied to the surface of the object to be heated, and then a glass cloth is applied to prevent damage to the heat insulating material, and then the core wire of the heating coil Requires a long work time for the entire construction, and depending on the diameter of the steel pipe, it is necessary to wind an extremely long coil core wire. As a result, the manufacturing cost of steel pipes and the like has increased.
[0005]
Therefore, in the previous application (Japanese Patent Application No. 8-96944), the applicant of the present application houses the heating coil C in the pocket p1 outside the bag-shaped mounting cover P as shown in FIGS. A heating coil mounting unit A1 in which a heat insulating material I is accommodated in a pocket p2 inside the cover P, and a current feeder A2 for applying a current to the heating coil C of the heating coil mounting unit A1 are provided. Induction heating apparatus A was provided.
[0006]
According to the induction heating apparatus A having the above configuration, since the heating coil C and the heat insulating material I are integrated together by the heating coil mounting unit A1, the heating coil mounting unit A1 is connected to the object to be heated (steel pipe) as shown in FIG. ) By attaching to W, the mounting of the heat insulating material I and the heating coil C is completed at the same time, thereby improving the workability related to the mounting of the heat insulating material and the heating coil to the heated object and greatly reducing the work time. Is achieved, and it becomes possible to reduce the working cost and the manufacturing cost.
[0007]
[Problems to be solved by the invention]
By the way, in the conventional induction heating apparatus A described above, the heating coil C accommodated in the pocket p1 of the mounting cover P is fixed by sewing to the mounting cover P using heat-resistant yarn, and the shape of the coil is In order to fix it without collapsing, it is necessary to tie a large number of locations in the heating coil to the mounting cover P, which takes a lot of time to create the heating coil mounting unit and is difficult to manufacture at low cost. Therefore, the manufacturing cost was increased.
[0008]
In addition, the mounting cover P in the conventional induction heating apparatus A is made of a heat-resistant cloth made of ceramic fibers knitted into a sheet, and this heat-resistant cloth has low durability against local friction, so it is housed inside. It is difficult to protect the heating coil C over a long period of time, and the mounting cover and the coil are consumed quickly and have a short life, resulting in an inconvenience that the consumables cost and the construction cost increase.
[0009]
In view of the actual situation as described above, the present invention makes it possible to improve workability related to attachment of a heat insulating material and a heating coil to an object to be heated, and to greatly reduce the work time and reduce the construction cost. An object of the present invention is to provide an induction heating apparatus that can achieve cost reduction and a method for manufacturing a heating coil mounting unit used in the induction heating apparatus.
[0010]
[Means for Solving the Problems]
In the present invention, in an induction heating apparatus comprising a heating coil attached to a heated body via a heat insulating material, and a current supply device for applying a current to the heating coil, heat resistance, flame retardancy and flexibility are achieved. A base sheet provided, a heating coil wound on a plane and attached to one surface of the base sheet and having flexibility, and attached to the other surface of the base sheet and having flexibility. The heating coil is adhered to one surface of the base sheet with an elastomer having a heat insulating material and having heat resistance, flame retardancy, flexibility and flexibility, and the outer surface of the heating coil is covered with the elastomer, the heat insulating material heat resistance on the other side surface of the base sheet, the heating coil instrumentation which includes a flexible comprising attached using an adhesive with the flexibility It is provided with a unit.
[0011]
According to the present invention, in the method of manufacturing a sheet-like heating coil mounting unit in which a heat insulating material is disposed on the heated side used in the induction heating device, one side of the base sheet having heat resistance, flame retardancy and flexibility After placing a flexible heating coil that is wound in a flat manner on the surface, a step of applying and curing a room temperature vulcanized silicone rubber in a state of covering the heating coil, and heat resistance, Attaching a heat insulating material having flexibility to the other surface of the base sheet having flame retardancy and flexibility using an adhesive having heat resistance and flexibility .
[0012]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, details of the present invention will be described with reference to the drawings.
1 to 4 show an example in which the present invention is applied to a high-frequency induction heating apparatus for working a steel pipe. As shown in FIG. 1, the high-frequency induction heating apparatus 1 is mounted on a steel pipe as a heated object. The heating coil mounting unit 1A and a current supply unit 1B for supplying a current to the heating coil mounting unit 1A.
[0013]
As shown in FIGS. 1 to 4, the heating coil mounting unit 1 </ b> A includes a base sheet 10, a heating coil 20 attached to the base sheet 10, and a heat insulating material 30. The heating coil 20 is made of an elastomer 40. It is attached to the base sheet 10.
[0014]
The base sheet 10 is made of a thick heat-resistant cloth made of twill-woven heat-resistant ceramic fibers and has a rectangular shape and has sufficient flexibility, heat resistance and flame retardancy, Strings 11 and 11 and strings 12 and 12 for attaching the heating coil mounting unit 1A to the steel pipe W by being bonded to each other are provided on the pair of edges.
[0015]
In addition, if the base sheet 10 mentioned above has sufficient softness | flexibility, heat resistance, and a flame retardance, not only the heat resistant cloth which consists of the heat resistant ceramic fiber mentioned above but appropriate heat resistant sheet material It is possible to produce using.
[0016]
In the base sheet 10 described above, when the heating coil mounting unit 1A is mounted on the steel pipe W, the heating coil 20 is mounted on the surface (one side surface) 10u located outside, while the mounting unit 1A is mounted on the steel pipe W. A heat insulating material 30 is attached to the surface (the other side surface) 10l located on the inner side when it is attached.
[0017]
The heat insulating material 30 is made of a heat insulating material having heat resistance, flame retardancy, and flexibility, and is formed in a rectangular shape that follows the planar shape of the base sheet 10. As described above, the other side of the base sheet 10 is formed. It is attached to the surface 101 using an adhesive having heat resistance, heat resistance and flexibility.
[0018]
On the other hand, as shown in FIGS. 1 and 2, the heating coil 20 has a coil portion 20A that is pre-formed by winding a core wire in a spiral shape on a plane, and a lead-out portion 20B that extends from the coil portion 20A. And the terminal 20C connected with the electric current supply machine 1B is provided in the edge part of the said derivation | leading-out part 20B.
[0019]
Here, the core wire of the heating coil 20 is preferably an electric wire that satisfies the conditions such that the insulation coating is thin and strong, the magnetic field generation efficiency is high, and the flexibility is high, and the heat resistant enamel-coated stranded copper wire It is preferable that
[0020]
Further, as shown in FIGS. 2 and 3, the coil portion 20A of the heating coil 20 is formed in such a manner that adjacent core wires 21 are closely wound and are wound closely, and as described above, one side of the base sheet 10 is formed. While being adhered to the surface 10 u by the elastomer 40, the outer surface of the coil portion 20 </ b> A is completely covered by the elastomer 40 without being exposed to the outside.
[0021]
In addition, the elastomer 40 which adheres the coil part 20A of the heating coil 20 to the base sheet 10 and covers the outer surface of the coil part 20A has heat resistance and flame retardancy of 250 ° C. or more, and has an outer shape of the steel pipe W. Any elastomer may be used as long as it is flexible so that it can be deformed. Silicone rubber and fluororubber are preferable, and silicone rubber is particularly preferable.
[0022]
In the heating coil mounting unit 1A, a sheet-like heat insulating material 30 is first attached to one surface (the other side surface) 10l of the base sheet 10, and then wound in a flat shape on the other surface (one side surface) 10u. After the heating coil 20 is placed, the fluidized elastomer 40 (room temperature vulcanized silicone rubber) is applied so as to cover the heating coil 20 and allowed to cure at room temperature.
[0023]
In the conventional induction heating apparatus, the coil portion of the heating coil is fixed at a predetermined position by sewing using heat-resistant yarn, whereas in the induction heating apparatus 1 according to the present invention, the elastomer is used as described above. 40, the coil portion 20A of the heating coil 20 is attached to a predetermined position of the base sheet 10, so that the heating coil mounting unit 1A can be created very easily without requiring complicated binding work. Since the manufacturing process can be shortened, the manufacturing cost is greatly reduced as compared with the conventional induction heating apparatus.
[0024]
Further, in the conventional induction heating device, the coil portion of the heating coil is protected by the mounting cover made of a heat-resistant cloth, whereas in the induction heating device 1 according to the present invention, the coil portion 20A is as described above. Since the outer surface is covered with the elastomer 40, the coil portion 20A can be reliably protected over a long period of time without requiring a mounting cover.
[0025]
Further, since the elastomer 40 has elasticity, the coil portion 20A is prevented from being damaged by an external impact, and the life of the heating coil 20 is greatly extended. According to the heating device 1, it is possible to significantly improve the durability as compared with the conventional induction heating device.
[0026]
On the other hand, a lead-out portion 20B of the heating coil 20 extends to the outside from the elastomer 40 covering the coil portion 20A, and the core portion constituting the lead-out portion 20B has a heat resistance made of a heat-resistant ceramic fiber. It is preferable to provide an insulating coating with a cloth (not shown).
[0027]
In order to mount the heating coil mounting unit 1A having the above-described configuration on the steel pipe W as the object to be heated as shown in FIG. 4, first, the heating coil mounting unit 1A is brought into contact with the outer peripheral surface of the steel pipe W. Wrap around the steel pipe W, then tie the string 11 and string 12 together to fix the heating coil mounting unit 1A to the outer periphery of the steel pipe W, and then attach the heating coil using a fastening band (not shown) as necessary. The unit 1A is fixed more firmly.
[0028]
Through the above-described operation, the heat insulating material 30 attached to the base sheet 10 is attached to the outer peripheral region of the steel pipe W, and the heating coil 20 is attached to the outer peripheral region of the heat insulating material 30 via the base sheet 10. .
That is, by attaching the heating coil mounting unit 1A to the steel pipe W, the mounting of the heat insulating material 30 on the steel pipe W and the mounting of the heating coil 20 are completed at the same time, and thus the time required for mounting the heat insulating material and the heating coil on the steel pipe W is reached. It can be very short.
[0029]
In addition, since the coil portion 20A of the heating coil 20 is formed in a spiral shape in advance, it is not necessary to wrap the core wire of the heating coil around the steel pipe W and construct it in a coil shape, and the workability related to the mounting of the heating coil is extremely high. As a result, it is possible to prevent an increase in work cost due to a reduction in work efficiency, in addition to shortening of the work time described above, and thus an increase in manufacturing cost related to the steel pipe W as a heated object. Can also be suppressed.
[0030]
After attaching the heating coil mounting unit 1A to the steel pipe W, the lead-out portion 20B of the heating coil 20 in the heating coil mounting unit 1A is connected to the current supply machine 1B (see FIG. 1), and current is applied to the heating coil 20. Thus, the heating operation for the steel pipe W is performed.
[0031]
Here, when the mounting unit 1A for heating is attached to the steel pipe W as described above, the heating coil 20 is mounted on the steel pipe W via the heat insulating material 30. The radiant heat is blocked by the heat insulating material 30, thereby preventing the heating coil 20 from being burned out.
[0032]
Moreover, the removal work can also be performed very easily in the same manner as the attachment work of the heating coil attachment unit 1A to the steel pipe W is extremely easy, and the entire body related to the attachment and removal of the heating coil attachment unit 1A to the steel pipe W. The work time is extremely short, and even if it is not a skilled worker, the work can be carried out in a short time, which is particularly effective in a high place work and a narrow place work where the work environment is severe.
[0033]
Furthermore, in the heating coil mounting unit 1A described above, the coil portion 20A of the heating coil 20 formed by winding the core wire 21 as densely as possible is fixed to the base sheet 10 using the elastomer 40. The heat generation amount per unit area in the mounting unit 1A is larger than that of the conventional heating coil mounting unit.
[0034]
That is, in the conventional induction heating apparatus, the heating coil is fixed at a predetermined position of the mounting cover by tying it with the heat-resistant yarn as described above, so that the coil shape of the core wire in the coil portion can be maintained. , It is necessary to tie each core wire that constitutes the coil part to the mounting cover. For this reason, a gap for passing heat-resistant yarn must be provided between adjacent core wires. Inevitably, a gap is generated between adjacent core wires.
[0035]
On the other hand, in the induction heating apparatus 1 of the present invention, the heating coil 20 is fixed to the base sheet 10 using the elastomer 40, in other words, a heat resistant yarn is used to fix the heating coil 20. Therefore, the adjacent core wires can be brought into close contact with each other in the coil portion 20A, and the number of coil turns can be increased as compared with the conventional induction heating device in the same installation area.
[0036]
Here, as is well known, when the current is constant, the output is proportional to the square of the number of turns of the coil. For example, a coil having a winding density of 103 (lines / m) with respect to a coil having a winding density of 68 (lines / m). The unit area calorific value ratio is 2.29.
Therefore, in the induction heating apparatus 1 of the present invention in which the number of coil turns can be set larger than that of the conventional induction heating apparatus in the same installation area, the heat generation amount per unit area can be increased.
[0037]
Further, during the heating operation of the steel pipe W, the heating coil 20 generates heat due to Joule heat, but the elastomer (silicone rubber or the like) 40 covering the coil portion 20A of the heating coil 20 has a relatively good thermal conductivity. Therefore, the heat generated from the coil portion 20A is effectively radiated and the heating coil 20 is prevented from being overheated, so that the deterioration of the heating coil 20 is suppressed as much as possible.
[0038]
FIG. 5 conceptually shows the shape of the coil portion in the heating coil, and the coil portion 20A of the embodiment gradually loops outward from the center portion like the coil portion Ea shown in FIG. The core wire e is wound in such a manner that the diameter is enlarged, but a loop L having substantially the same shape as the coil portion Eb shown in FIG. 5B or the coil portion Ec shown in FIG. It is also possible to form the coil portion of the heating coil by winding the core wire e while sequentially shifting in the horizontal direction or the oblique direction in the figure.
[0039]
In addition, also in each coil part Ea, Eb, Ec shown in FIG. 5, it is needless to say that the adjacent core wires are arranged as close as possible, and the shape of the lube in the coil part is illustrated. It is possible to set an arbitrary shape such as an elliptical shape or a perfect circular shape based on various conditions such as the size of the object to be heated as well as the shape approximated to the rectangle.
[0040]
FIG. 6 shows a mode in which the heating coil mounting unit 1A is accommodated in the mounting cover 50 and used. When the heat insulating material 30 is a ceramic heat insulating material, specifically, a non-woven fabric made of ceramic fibers is used. It is preferable to carry out.
[0041]
The mounting cover 50 is made of a heat-resistant cloth made of twilled heat-resistant ceramic fibers into a sheet shape, and is formed into a bag shape having one opening 50i. Are attached to the steel pipe W. Strings 51 and 51 and strings 52 and 52 are provided, respectively.
[0042]
Here, the heating coil mounting unit 1A in FIG. 6 is basically different from the embodiment shown in FIGS. 1 to 4 except that the material of the heat insulating material 30 is different. A detailed description of the configuration is omitted.
[0043]
As described above, when the heating coil mounting unit 1A is housed in the mounting cover 50, the heat insulating material 30 can be prevented from coming into contact with the worker, and the material of the heat insulating material 30 is the skin of the worker. The discomfort caused by touching can be removed.
[0044]
The core wire constituting the heating coil is a wire other than a heat-resistant enamel-coated stranded copper wire as long as it satisfies the above-mentioned conditions such as a thin and strong insulation coating, a high magnetic field generation efficiency, and a high flexibility. Can be used.
[0045]
Further, in place of the strings 11 and 12 in FIG. 1 and the strings 51 and 52 in FIG. 6, as a means for fixing the heating coil mounting unit to the steel pipe, a hook-and-loop fastener made of hook tape and loop tape, hook and eye Needless to say, various fastening means such as a hook and hook made of a ball and a snap made of a ball side and a socket side can be adopted.
[0046]
Furthermore, although the example which applied this invention to the high frequency induction heating apparatus was shown in the Example mentioned above, this invention can be applied to a low frequency induction heating apparatus and a triple frequency induction heating apparatus, or a commercial frequency induction heating apparatus. Needless to say, the object to be heated is not limited to the steel pipe shown in the embodiment, and various objects to be heated such as a steel frame and a pressure vessel can be used as a work object.
[0047]
【The invention's effect】
As described above in detail, in the induction heating apparatus according to the present invention, a heating coil wound in a spiral shape on a plane is attached to one surface of the base sheet, and a heat insulating material is attached to the other surface of the base sheet. By configuring the heating coil mounting unit, the heating coil and the heat insulating material are integrated together by the heating coil mounting unit, and by attaching the heating coil mounting unit to the heated object, the heat insulating material for the heated object and Mounting with the heating coil is completed at the same time, thereby improving workability and drastically shortening the work time related to the installation of the heat insulating material and the heating coil on the object to be heated, thereby reducing work costs and manufacturing costs. It becomes possible.
[0048]
In addition, in the induction heating device and the method for manufacturing the heating coil mounting unit according to the present invention, the heating coil is attached to the one side surface of the base sheet using an elastomer, so that the heating coil is fixed by sewing. Compared with the conventional induction heating device, the heating coil mounting unit can be made very easily and the manufacturing process can be shortened, so that the manufacturing cost can be greatly reduced, and further the heating coil winding Since the cycle density can be maximized, an apparatus with good induction heating efficiency can be provided.
[0049]
Furthermore, in the method of manufacturing the induction heating apparatus and the heating coil mounting unit according to the present invention, since the outer surface of the heating coil is covered with the elastomer, the conventional induction in which the heating coil is covered with a cover made of a heat-resistant cloth. Compared to the heating device, the heating coil can be reliably protected over a long period of time, and the durability can be greatly improved.
[Brief description of the drawings]
FIG. 1 is an overall perspective view of an induction heating apparatus according to the present invention, with a part of a heating coil mounting unit broken away.
FIG. 2 is an overall plan view showing a heating coil mounting unit of the induction heating apparatus according to the present invention.
FIG. 3 is a cross-sectional view taken along line III-III in FIG. 2 showing a cross section of the heating coil mounting unit.
FIG. 4 is an external perspective view showing a mounting state of a heating coil mounting unit to a heated body in the induction heating apparatus of the present invention.
FIGS. 5A to 5C are conceptual diagrams showing the shape of the heating coil in the heating coil mounting unit of the induction heating apparatus according to the present invention.
FIG. 6 is a perspective view showing a heating coil mounting unit and a mounting cover of the induction heating apparatus according to the present invention.
FIG. 7 is a conceptual diagram showing a conventional induction heating apparatus.
FIGS. 8A and 8B are a cutaway side view and a top view of main parts showing a heating coil mounting unit in a conventional induction heating apparatus.
FIG. 9 is an external perspective view showing a mounting state of a heating coil mounting unit to a heated body in a conventional induction heating apparatus.
[Explanation of symbols]
1 ... induction heating device,
1A ... heating coil mounting unit,
1B ... current supply machine,
10 ... Base sheet,
10u ... one side surface,
10l ... the other side surface,
20 ... heating coil,
20A ... Coil part,
20B ... derivation part,
20C ... terminal,
21 ... Core wire,
30 ... heat insulating material,
40. Elastomer,
50 ... device cover,
W: Steel pipe (object to be heated).

Claims (7)

An induction heating apparatus comprising: a heating coil mounted on a body to be heated via a heat insulating material; and a current supply device for applying a current to the heating coil,
A base sheet having heat resistance, flame retardancy, and flexibility; a heating coil wound on a plane and attached to one surface of the base sheet; and the other side of the base sheet The heating coil is attached to one surface of the base sheet with an elastomer having heat resistance, flame resistance, flexibility, and flexibility. In addition, the outer surface of the heating coil is covered with the elastomer, and the heat insulating material is attached to the other surface of the base sheet using an adhesive having heat resistance and flexibility . An induction heating apparatus comprising a heating coil mounting unit.   2. The induction heating apparatus according to claim 1, wherein a core wire of the heating coil in the heating coil mounting unit is a heat-resistant enamel-coated stranded copper wire.   2. The induction heating apparatus according to claim 1, wherein the elastomer in the heating coil mounting unit is silicone rubber.   2. The induction heating apparatus according to claim 1, wherein the heating coil mounting unit is housed in a mounting cover. A method for manufacturing a sheet-shaped heating coil mounting unit in which a heat insulating material is disposed on a heated side used in an induction heating device,
After placing a flexible heating coil on a surface of one side of a base sheet with heat resistance, flame retardancy and flexibility, the room temperature in a fluid state in a manner covering the heating coil Applying and curing vulcanized silicone rubber;
Attaching a heat insulating material with flexibility to the other surface of the base sheet with heat resistance, flame retardancy and flexibility using an adhesive with heat resistance and flexibility ;
The manufacturing method of the heating coil mounting unit used for the induction heating apparatus characterized by having.   The induction heating apparatus according to claim 1, wherein adjacent core wires in the heating coil are in close contact with each other.   6. The method of manufacturing a heating coil mounting unit according to claim 5, wherein adjacent core wires in the heating coil are brought into close contact with each other.

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