Electromagnetic induction heating apparatus and light alloy wheel manufacturing method
10375770 ยท 2019-08-06
Assignee
Inventors
Cpc classification
F27D11/12
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H05B6/10
ELECTRICITY
International classification
H05B6/10
ELECTRICITY
F27D11/12
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
To show an electromagnetic induction heating apparatus in which an object to be heated such as a half-finished light alloy wheel can be heated efficiently to have a predetermined temperature in a short time. An electromagnetic induction heating apparatus 1 includes a rotating body 2 with a plurality of magnets 21 arranged such that the same pole is positioned on the side of an object to be heated 8 and a rotation driving motor 3 for rotating the rotating body 2, in which the object to be heated 8 is heated by an induced current generated when the rotating body 2 is rotated. By controlling the distance D between the magnets 21 of the rotating body 2 and the object to be heated 8 with a moving motor 6, a light alloy wheel or the like, which has a high thermal expansion coefficient, can be well-heated efficiently.
Claims
1. An electromagnetic induction heating apparatus comprising: a rotating body with a plurality of magnets arranged such that the same pole is positioned on a side of an object to be heated; a rotation driving means for rotating the rotating body; a temperature sensor for measuring a temperature of the object to be heated; and a moving means for moving at least one of the rotating body and the object to be heated to change a distance between the rotating body and the object to be heated, wherein the rotating body is arranged with the plurality of magnets, wherein the object to be heated is a half-finished light alloy wheel, wherein the temperature sensor measures first temperature of the half-finished light alloy wheel on a side of the rotating body and second temperature of the half-finished light alloy on an opposite side of the rotating body, wherein the moving means changes the distance based on the first temperature and the second temperature, wherein the rotation driving means changes a rotation speed of the rotating body based on the first temperature and the second temperature, and wherein the object to be heated is heated by an induced current generated when the rotating body is rotated.
2. The electromagnetic induction heating apparatus according to claim 1, wherein at least one of the rotation speed of the rotating body and the distance between the magnets and the object to be heated is changed such that the difference between the first temperature and the second temperature becomes 50 to 150 C.
3. A light alloy wheel manufacturing method comprising a heating step of heating a half-finished light alloy wheel through electromagnetic induction, wherein in the heating step, the half-finished light alloy wheel is heated by an induced current generated when the rotating body of the electromagnetic induction heating apparatus, the electromagnetic induction heating apparatus comprising: a rotating body with a plurality of magnets arranged such that the same pole is positioned on a side of the half-finished light alloy wheel to be heated; a rotation driving means for rotating the rotating body; a temperature sensor for measuring a temperature of the half-finished light alloy wheel to be heated; and a moving means for moving at least one of the rotating body and the half-finished light alloy wheel to be heated to change a distance between the rotating body and the half-finished light alloy wheel to be heated, wherein the rotating body is arranged with the plurality of magnets, wherein the temperature sensor measures first temperature of the half-finished light alloy wheel on a side of the rotating body and second temperature of the half-finished light alloy on an opposite side of the rotating body, wherein the moving means changes the distance based on the first temperature and the second temperature, wherein the rotation driving means changes a rotation speed of the rotating body based on the first temperature and the second temperature, and wherein the electromagnetic induction hearting apparatus is rotated below the half-finished light alloy wheel.
4. The light alloy wheel manufacturing method according to claim 3, further comprising: a casting step of forming the half-finished light alloy wheel; and a processing step of processing the light alloy wheel heated in the heating step.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
MODES FOR CARRYING OUT THE INVENTION
(12) (First Embodiment)
(13) Embodiments of the present invention will hereinafter be described with reference to the accompanying drawings.
(14)
(15)
(16) As the magnets 21, ferrite magnets, samarium-cobalt magnets (SmCo-based magnets), rare-earth magnets such as neodymium magnets (NdFeB-based magnets), alnico magnets (AlNiCo magnets), and the like can be employed. Magnets having high magnetic energy such as rare-earth magnets are preferable in terms of heating the object to be heated 8 efficiently.
(17)
(18)
(19) The rotation driving motor 3 (see
(20) The distance measuring means 4 is for measuring a distance D between the end of each magnet 21 of the rotating body 2 on the side of the object to be heated 8 and the object to be heated 8. The distance measuring means 4 includes, for example, a means for detecting a change in the electrostatic capacity between each magnet 21 of the rotating body 2 and the object to be heated 8 or a change in a laser beam passing through the clearance gap therebetween.
(21) While
(22) The temperature measuring means 5 measures the temperature of the object to be heated 8 and outputs the results to the control means 7. As the temperature measuring means 5, a known temperature sensor such as a thermocouple can be employed. While it may be arranged such that the temperature of the object to be heated 8 is measured at one site as shown in
(23) The moving motor 6 moves the rotation driving motor 3 in a direction parallel to the rotating shaft 22 to change the distance D between the rotating body 2 and the object to be heated 8. For example, in a case where it is measured by the distance measuring means 4 that the object to be heated 8 is thermally expanded and thereby the distance D is reduced, the rotation driving motor 3 can be moved in a direction away from the object to be heated 8 such that the distance D is kept at a level for good heating efficiency.
(24) While
(25) The control means 7 is electrically connected with the above-described rotation driving motor 3, distance measuring means 4, temperature measuring means 5, and the moving motor 6 in a wired or wireless manner to respectively control them and can be configured using, for example, a computer, etc. Control by the control means 7 will hereinafter be described.
(26) The control means 7 controls the rotation driving motor 3 and the moving motor 6 using the distance D measured by the distance measuring means 4. In a case where expansion/deformation of the object to be heated 8 due to heating is detected, the rotation driving motor 3 is stopped and/or the rotating body 2 is moved by the moving motor 6. This can prevent the rotating body 2 and the object to be heated 8 from coming into contact with each other. For example, in a case where the distance D between the rotating body 2 and the object to be heated 8 is reduced to a level of possible risk of contact therebetween, the rotating body 2 is moved in a direction away from the object to be heated 8. At this time, keeping the distance D at a level for good heating efficiency allows for achieving good heating efficiency.
(27) The control means 7 can control the rotation driving motor 3 and the moving motor 6 using the temperature of the object to be heated 8 measured by the temperature measuring means 5. For example, the temperature of the object to be heated 8 can be finely controlled by keeping the distance D and the rotation speed at a level for high heating efficiency until the object to be heated 8 reaches a predetermined temperature, while by changing the distance D and the rotation speed as the targeted temperature gets near. At the time when the object to be heated 8 reaches the predetermined temperature, the rotation driving motor 3 may be stopped and the rotating body 2 may be moved in a direction away from the object to be heated 8.
(28) In a case where the electromagnetic induction heating apparatus 1 includes a plurality of the distance measuring means 4, the control means 7 may control each part using the maximum value or the minimum value of a plurality of distances D detected.
(29) The object to be heated 8 is made of material with which an eddy current is generated by changing a magnetic field. The object to be heated 8 includes, for example, an article made of aluminum alloy containing aluminum, etc., specifically an aluminum sash, an aluminum wheel, etc. Also, an article made of light alloy, which is mainly made of light metal such as aluminum, magnesium, titanium may be heated as the object to be heated 8.
(30)
(31) (Second Embodiment)
(32) An aluminum wheel manufacturing method will be described in which the electromagnetic induction heating apparatus 1 described in the first embodiment is used to heat a half-finished aluminum wheel made of aluminum alloy as an example light alloy wheel.
(33)
(34) (Casting Step S1)
(35) In the casting step S1, molten metal is poured into a cavity formed by a mold, and after cooling, the mold is opened to form a half-finished aluminum wheel as an aluminum alloy cast. In a case of manufacturing an integrated (one-piece type) aluminum wheel, a rim portion and a disk portion are formed integrally. In a case of manufacturing a separated (two-piece type) aluminum wheel, a rim portion and a disk portion are formed separately. In both cases, the rim portion is partially deformed in the following processing step S3 to have a predetermined shape.
(36) In the present invention, the aluminum alloy cast formed in the casting step S1 is called a half-finished aluminum wheel (near net shape).
(37) (Heating Step S2)
(38) In the heating step S2, the half-finished aluminum wheel is preliminarily heated to a temperature suitable for processing in the following processing step S3.
(39) A heating furnace has conventionally been used to heat, before a processing step, a half-finished aluminum wheel to a temperature of, for example, about 150 to 400 C. suitable for processing. However, heating using the heating furnace takes a long time to heat the half-finished aluminum wheel to a predetermined temperature and requires a large installation space, which lowers the economic efficiency of aluminum wheel manufacturing.
(40) Also, in the conventional heating using the heating furnace, the entire half-finished aluminum wheel is heated to a predetermined temperature. However, only the rim portion on one of the side surfaces of the half-finished aluminum wheel is processed in the processing step S3. For example, in a case of processing an integrated aluminum wheel, it is preferable to keep the other side surface at a lower temperature so that the disk portion formed in the casting step S1 is not deformed in the processing step S3. Accordingly, if it is possible to heat one of the side surfaces of the half-finished aluminum wheel to undergo plastic deformation to a temperature higher than that of the other side surface, the efficiency of aluminum wheel manufacturing can be further increased.
(41) Therefore, in the heating step S2 of the aluminum wheel manufacturing method of the present embodiment, the half-finished aluminum wheel is heated through electromagnetic induction using the electromagnetic induction heating apparatus 1. The electromagnetic induction heating apparatus 1 can heat the half-finished aluminum wheel efficiently and can be installed in a narrow space. It is therefore possible to save time, energy, space, etc., required for aluminum wheel manufacturing.
(42) In addition, by using the electromagnetic induction heating apparatus 1, it is possible to heat one of the side surfaces of the half-finished aluminum wheel selectively to a high temperature, that is, it is possible to heat the half-finished aluminum wheel such that a temperature gradient is generated therein. Thus, in the processing step S3, one of the side surfaces can have a temperature suitable for processing, while the other side surface can have a temperature at which no unintended deformation or the like can occur.
(43) According to the heating step S2 using the electromagnetic induction heating apparatus 1, it is possible to heat the half-finished aluminum wheel to, for example, about 150 to 500 C.
(44) (Processing Step S3)
(45) In the processing step S3, the half-finished aluminum wheel formed in the casting step S1 is deformed into a predetermined shape. The processing step S3 includes, for example, a plastic working step and a forging (pressing) step.
(46) In the plastic working step, the half-finished aluminum wheel is placed within and rotated together with a pressure resistant formwork and, at the same time, a roller is pressed against and moved on a portion to be formed into a rim portion at a predetermined pressure to form a predetermined shape. In the plastic working step, processing is performed in which the rim portion is stretched which is formed thicker in the half-finished aluminum wheel than in the finished product.
(47) In the forging step, the half-finished aluminum wheel is placed within a pressure resistant mold and formed by a high-pressure press into an aluminum wheel of a predetermined shape. The forging step is preferably used for manufacturing of aluminum wheels for large-sized vehicles such as buses and trucks.
(48) It is preferable that at the time when the processing step S3 is completed, the entire aluminum wheel has a uniform temperature in terms of preventing deformation of the finished aluminum wheel. In a case of plastic working for a predetermined shape, the rim portion undergoes a larger decrease in the temperature on one side to be stretched in the processing step S3 than on the other side. For this reason, if the rim portion on one side to be processed has a higher temperature at the start of the processing step S3, the aluminum wheel can have a reduced strain. From this point of view, the temperature difference between the rim portion on one side to be stretched and the rim portion on the other side is preferably 100 C. or lower, more preferably 50 C. or lower, and still more preferably 30 C. or lower when the processing step S3 is completed. It is noted that the temperature difference here means the average value of the respective temperatures of the rim portions on one side to be stretched and on the other side.
(49)
(50) As shown in
(51) In the heating step S2 (see
(52) In terms of the heating efficiency in the heating step S2 and the side surfaces of the half-finished aluminum wheel 81 having temperatures suitable in the processing step S3, the difference between the first and second temperatures measured by the temperature measuring means 5A and 5B in the heating step S2 is preferably 50 to 150 C., more preferably 70 to 130 C., and still more preferably 80 to 130 C.
(53) It is noted that the second embodiment describes the case of an aluminum wheel manufacturing method in which the electromagnetic induction heating apparatus 1 according to the present invention is used. In a case of manufacturing an aluminum sash, it is necessary to heat a columnar aluminum alloy raw material to a predetermined temperature before passing through a die into a predetermined shape. In this case, using the electromagnetic induction heating apparatus 1 according to the present invention allows the columnar aluminum alloy raw material to be heated such that a temperature gradient is generated therein. If the end of the columnar aluminum alloy raw material to first pass through the die is heated to have a higher temperature than the end to later pass through the die, the aluminum sash can be made with a uniform temperature when the processing step is completed, whereby it is possible to efficiently manufacture aluminum sashes with the strain due to temperature non-uniformity being reduced.
EXAMPLES
(54) The present invention will hereinafter be described more specifically according to examples, however, the present invention is not restricted thereto.
(55) With an electromagnetic induction heating apparatus 1 configured as follows (see
(56) Object to be heated
(57) Material: made of aluminum allow Profile: diameter 425 mm118 mm Weight: 11.8 kg Specific heat: 900 (J/Kg K) (20 C.) Thermal conductivity: 204 (W/m K)
First Example
(58) An electromagnetic induction heating apparatus 1 was used including a rotating body 2 with 28 neodymium magnets evenly arranged on a circumference having a diameter of 390 mm and a rotation driving motor 3 having an output of 11 KW. The distance D from the object to be heated 8 to the magnets 21 of the rotating body 2 was set to 2.0 mm, 2.5 mm, and 3.0 mm. For each distance, the rotation speed of the rotating body 2 was changed to measure the time (seconds) required for the difference between the room temperature and the temperature of the object to be heated 8 to reach 100 C., that is, for the temperature of the object to be heated 8 to rise by 100 C. from the room temperature. Table 1 and
(59) TABLE-US-00001 TABLE 1 Heating time (seconds) required for 100 C. rise from the room temperature D = 2.0 mm D = 2.5 mm D = 3.0 mm Rotation Magnetic Magnetic Magnetic speed flux density flux density flux density (rpm) 4.65 KG 4.50 KG 4.39 KG 500 494 652 600 350 489 700 255 349 800 201 274 900 163 219 276 1000 147 198 237 1100 129 165 201 1200 110 146 167 1300 95 129 148 1400 90 111 1500 84 95 1600 77 93
Second Example
(60) With the same electromagnetic induction heating apparatus 1 as in the first example, the distance D from the end of the object to be heated 8 to the magnets 21 of the rotating body 2 was set to 2.6 mm, 2.8 mm, and 3.0 mm. For each distance, the rotation speed of the rotating body 2 was changed to measure the time (seconds) required for the difference between the room temperature and the temperature of the object to be heated 8 to reach 200 C., that is, for the temperature of the object to be heated 8 to rise by 200 C. from the room temperature. Table 2 and
(61) TABLE-US-00002 TABLE 2 Heating time (seconds) required for 200 C. rise from the room temperature D = 2.6 mm D = 2.8 mm D = 3.0 mm Rotation Magnetic Magnetic Magnetic speed flux density flux density flux density (rpm) 4.61 KG 4.45 KG 4.39 KG 1400 597 1500 506 561 1600 471 465 1700 345 419 453 1750 345 435 471 1800 327 435 471 1850 318 399 471 1900 309
Third Example
(62) With the same electromagnetic induction heating apparatus 1 as in the first example, the object to be heated of D=2.0 mm, which required the shortest heating time in the first example, was heated at a rotation speed of 1750 rpm for 846 seconds, and a temperature of 350 C. was achieved.
Fourth Example
(63) The electromagnetic induction heating apparatus 1 used was different from that in the first example in that the rotating body 2 includes ferrite magnets instead of neodymium magnets and that the rotation driving motor 3 has an output of 3.5 KW. The distance D from the end of the object to be heated 8 to the magnets 21 of the rotating body 2 was set to 1.8 mm, 2.0 mm, 2.2 mm, 2.4 mm, 2.6 mm, and 2.8 mm. For each distance, the rotation speed of the rotating body 2 was changed to measure the time (seconds) required for the object to be heated 8 at the room temperature to reach 40 C. Table 3 and
(64) TABLE-US-00003 TABLE 3 Heating time (seconds) required for 40 C. rise from the room temperature D = 1.8 mm D = 2.0 mm D = 2.2 mm D = 2.4 mm Rotation Magnetic Magnetic Magnetic Magnetic speed flux density flux density flux density flux density (rpm) 0.1520 KG 0.1491 KG 0.1461 KG 0.1431 KG 2900 324 320 385 392 3000 402 371 392 410 3100 368 381 379 420 3200 318 337 366 421 3300 331 319 323 344 3400 335 344 368 417 3500 322 354 365 520 3700 441 D = 2.6 mm D = 2.8 mm D = 3.0 mm D = 3.2 mm Rotation Magnetic Magnetic Magnetic Magnetic speed flux density flux density flux density flux density (rpm) 0.1400 KG 0.1366 KG 0.1339 KG 0.1310 KG 2900 505 510 3000 420 459 3100 410 464 493 558 3200 478 548 604 572 3300 384 420 474 614 3400 505 529 653 656 3500 516 501 499 506 D = 3.4 mm D = 3.6 mm Rotation Magnetic Magnetic speed flux density flux density (rpm) 0.1281 KG 0.1251 KG D = 3.8 mm 3100 631 786 3200 629 649 786 3300 745 589 3400 623 613 647 3500 538 614
(65) The following are found from the results of the first to fourth examples: (1) In both the first to third examples in which neodymium magnets were used and the fourth example in which anisotropic ferrite magnets were used, it was possible to heat the aluminum alloy objects to be heated through magnetic induction. (2) It was possible to heat the aluminum alloy objects to be heated to 350 C., which was sufficient for processing, by using neodymium magnets. (3) Neodymium magnets and anisotropic ferrite magnets have their respective different rotation speeds at which a good heating efficiency can be achieved. In these examples, about 1750 (rpm) was best for neodymium magnets, while about 3100 (rpm) was best for anisotropic ferrite magnets, respectively. (4) Reducing the distance D between the object to be heated and the magnets had a beneficial effect on increasing the heating efficiency. (5) When heated under the condition that the difference between the first temperature of the object to be heated on the side of the rotating body and the second temperature on the opposite side was about 100 C., the heating efficiency was better than when heated under the condition of about 200 C.
INDUSTRIAL APPLICABILITY
(66) The electromagnetic induction heating apparatus according to the present invention is useful as, for example, an apparatus for efficiently heating a half-finished light alloy wheel or the like to a predetermined temperature suitable for a processing step in a short time.