High frequency induction heating apparatus and processing apparatus

Abstract

Provided is a high frequency induction heating apparatus capable of quenching a workpiece having an outward flange, over the whole circumference by means of a frequency with which a penetration depth of an electromagnetic wave is larger than a sheet thickness of the workpiece The high frequency induction heating apparatus includes a high frequency induction heating coil used for heating a long hollow steel workpiece having a closed cross section and an outward flange, in 3DQ in which a bending member is manufactured from the workpiece The high frequency induction heating coil includes a magnetic material core facing each other between which both faces of the outward flange are interposed, having a distance from both faces, and an induction heating coil connected to the magnetic material core and arranged surrounding an outer circumference of a general portion where the outward flange is excluded from the workpiece.

Claims

1. A high frequency induction heating apparatus comprising: a high frequency induction heating coil used for heating a long hollow steel workpiece having a closed cross section and an outward flange having two faces, wherein the high frequency induction heating coil comprises a magnetic material core and an induction heating coil, wherein the induction heating coil is connected to the magnetic material core and arranged surrounding an outer circumference of a portion of the workpiece where the outward flange is excluded from the workpiece, the induction heating coil further comprising a first portion connected to a high frequency power generator, a second portion connected to the first portion and extended in the longitudinal direction of the workpiece, a third portion connected to the second portion and arranged surrounding the outer circumference of the portion of the workpiece, a fourth portion connected to the third portion and extended in the longitudinal direction of the workpiece, and a fifth portion connecting the fourth portion and the high frequency power generator, the fifth portion being positioned adjacent to the first portion, and the magnetic material core is positioned between the second portion and the fourth portion and positioned to surround the fourth portion, and the magnetic material core has two portions arranged facing each other so that both of the faces of the outward flange are interposed between the two portions, the magnetic material core having a distance from the both of the faces.

2. The high frequency induction heating apparatus according to claim 1, wherein a current which flows in the second portion and a current which flows in the fourth portion flow in the opposite direction from each other.

3. The high frequency induction heating apparatus according to claim 1, wherein the following Formula 1 is satisfied, wherein L (mm) is a length of the magnetic material core in the longitudinal direction of the workpiece, f (kHz) is a current frequency of the induction heating coil, and v (mm/s) is a moving speed of the high temperature portion of the workpiece $\begin{array}{cc}\frac{21}{f}\sqrt{V}<L<\frac{35}{f}\sqrt{V}.& \left(1\right)\end{array}$

4. A processing apparatus comprising: the high frequency induction heating apparatus according to any one of claims 1, 2, and 3; a water-cooling apparatus arranged adjacent to a downstream side of the high frequency induction heating apparatus; and an articulated robot arranged on a downstream side of the cooling apparatus and supporting the workpiece to add an external force to the workpiece.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1 includes an explanation drawing showing a high frequency induction heating coil of the high frequency induction heating apparatus according to the present invention;

(2) FIG. 1A is a perspective view;

(3) FIG. 1B is a view seen from a direction of the arrow A in FIG. 1A; and

(4) FIG. 1C is a view seen from a direction of the arrow B in FIG. 1A;

(5) FIG. 2 includes an explanation drawing showing the principle of heating an outward flange by means of the present invention;

(6) FIG. 2A is a view of the magnetic material core and the induction heating coil seen from a direction of the arrow D in FIG. 1A;

(7) FIG. 2B is a view of the magnetic material core and the induction heating coil seen from a direction of the arrow A in FIG. 1A;

(8) FIG. 3 includes a graph showing calculation results by a numerical analysis in a case where a conventional high frequency induction heating coil shown in FIGS. 12A and 12B is used;

(9) FIG. 3A is a graph showing a relationship between the frequency of the current of the high frequency induction heating coil and the temperature of the outward flange;

(10) FIG. 3B is a graph showing a relationship between the frequency and the electric power;

(11) FIG. 4 includes a graph showing calculation results by a numerical analysis in a case where the high frequency induction heating coil according to the present invention shown in FIGS. 1A to 1C is used;

(12) FIG. 4A is a graph showing a relationship between the length of the magnetic material core (core length) in the longitudinal direction of the workpiece and the temperature of the outward flange;

(13) FIG. 4B is a graph showing a relationship between the core length and the electric power consumption;

(14) FIG. 5 is a graph showing a relationship between the core length of the magnetic material core and the heating temperature of the outward flange in a case where the current frequency of the high frequency induction heating coil is 50 kHz;

(15) FIG. 6 is a graph showing a relationship between the core length of the magnetic material core and the heating temperature of the outward flange in a case where the current frequency of the high frequency induction heating coil is 100 kHz;

(16) FIG. 7 is a graph showing results of sorting out the minimum value of the adequate core length of the magnetic material core shown in Tables 1 to 3;

(17) FIG. 8 is a graph showing results of sorting out the maximum value of the adequate core length of the magnetic material core;

(18) FIG. 9 is a graph showing examination results of the frequency dependence of the coefficient a in the graphs in FIGS. 7 and 8;

(19) FIG. 10 includes an explanation drawing showing the temperature distribution of the workpiece in a circumference direction in a case where the workpiece is heated by means of the high frequency induction heating coil at a frequency of 50 kHz and a transporting speed of 20 mm/s;

(20) FIG. 10A shows an example of the present invention;

(21) FIG. 10B shows a conventional example;

(22) FIG. 11 is an explanation drawing showing a situation in which a bending member is manufactured by 3DQ;

(23) FIG. 12 includes an explanation drawing showing a situation in which a high frequency quenching and a bending processing are carried out at the same time by means of 3DQ to a hollow steel workpiece having a closed cross section and an outward flange;

(24) FIG. 12A is a perspective view;

(25) FIG. 12B is a cross-sectional view taken along the line C-C in FIG. 12A;

(26) FIG. 13 includes an explanation drawing conceptually showing a reason why the outward flange of the workpiece is not heated;

(27) FIG. 13A shows a flow of a coil current which flows in the high frequency induction heating coil and a flow of an eddy current generated in the workpiece, in a case where the penetration depth of an electromagnetic wave at the general portion of the workpiece from which the outward flange is excluded is larger than the sheet thickness of the workpiece;

(28) FIG. 13B shows flows of the coil current and the eddy current in a case where the penetration depth of an electromagnetic wave at the outward flange of the workpiece is larger than the sheet thickness of the workpiece;

(29) FIG. 13C shows flows of the coil current and the eddy current in a case where the penetration depth of an electromagnetic wave at the general portion of the workpiece is smaller than the sheet thickness of the workpiece;

(30) FIG. 13D shows flows of the coil current and the eddy current in a case were the penetration depth of an electromagnetic wave at the outward flange of the workpiece is smaller than the sheet thickness of the workpiece;

(31) FIG. 14 is a graph showing a relationship between the frequency and penetration depth of the current of the high frequency induction heating coil.

DESCRIPTION OF EMBODIMENTS

(32) The present invention will be described with reference to the drawings. FIG. 1 is an explanation drawing showing a high frequency induction heating coil 11 in a high frequency induction heating apparatus 10 of the present invention. FIG. 1A is a perspective view, FIG. 1B is a view seen from a direction shown by the arrow Ain FIG. 1A, and FIG. 1C is a view seen from a direction shown by the arrow B in FIG. 1A.

(33) As shown in FIGS. 1A to 10, the high frequency induction heating apparatus 10 is provided with a high frequency induction heating coil 11 and carries out high frequency induction heating to a workpiece 12 by means of the high frequency induction heating coil 11.

(34) The workpiece 12 is a long hollow member made of steel, having a closed cross section and consisting of an outward flange 12a and a general portion 12b which is a portion where the outward flange 12a is excluded from the workpiece 12. At the outward flange 12a, two steel sheets are joined by means of an appropriate means (e.g. welding such as spot welding), in a manner to overlap with each other.

(35) The high frequency induction heating coil 11 is used for heating the workpiece 12, when 3DQ is carried out in which a bending member is manufactured by forming a high temperature portion which moves in the longitudinal direction of the workpiece 12 in the workpiece 12, and at the same time adding an external force to the high temperature portion.

(36) The high frequency induction heating coil 11 includes a magnetic material core 13 and an induction heating coil 14. The magnetic material core 13 is a so-called ferrite core, which is a ferromagnetic body of a Fe oxide sintered as a ceramic. The magnetic material core 13 has a material having a magnetic property and high electric resistance. Specifically, the magnetic material core 13 has a relative magnetic permeability of at least 3 or more, and an electrical resistivity of at least 1 m or more . The material of the magnetic material core 13 is not necessarily limited to the ferrite core, and can be another material having the same or more of physical property.

(37) The magnetic material core 13 is arranged having a distance from the both faces of the outward flange 12a of the workpiece 12 (one face 12a-1 and the other face 12a-2) as shown in FIG. 10. The magnetic material core 13 is arranged facing each other, and the both faces 12a-1 and 12a-2 are interposed between the magnetic material core 13.

(38) On the other hand, the induction heating coil 14 is connected to the magnetic material core 13 and arranged in a manner to surround an outer circumference of the general portion 12b, where the outward flange 12a is excluded from the workpiece 12. That is, the induction heating coil 14 includes: a first portion 14-1 connected to a high frequency power generator which is not shown; a second portion 14-2 connected to the first potion 14-1 and extended in the longitudinal direction of the workpiece 12; a third portion 14-3 connected to the second portion 14-2 and arranged in a manner to surround the circumference of the general portion 12b of the workpiece 12; a fourth portion 14-4 connected to the third portion 14-3 and extended in the longitudinal direction of the workpiece 12; and a fifth portion 14-5 connecting the fourth portion 14-4 and the high frequency power generator not shown.

(39) The symbol 15 in FIG. 1B shows an insulating plate. The transporting direction of the workpiece 12 is a direction in which the fifth portion 14-5 of the induction heating coil 14 in FIGS. 1A to 10 is determined as an upstream side, and the third portion 14-3 of the induction heating coil 14 is determined as a downstream side.

(40) As can be seen from FIGS. 1A to 10, the magnetic material core 13 is arranged in a manner to cross the fourth portion 14-4 of the induction heating coil 14. Also, the magnetic material core 13 has portions 13-1 and 13-2 parallel to the outward flange 12a, on the upstream side in the transporting direction of the workpiece 12, that is, on the downstream side in the moving direction of the high temperature portion in the workpiece 12. The portions 13-1 and 13-2 generate a magnetic flux to the outward flange 12a in a vertical direction.

(41) The arrow shown at the vicinity of the induction heating coil 14 in FIG. 1A shows a direction of the current which flows in the induction heating coil 14. As shown in FIG. 1A, the magnetic material core 13 is arranged in a manner to be positioned between two portions 14-2 and 14-4 of the induction heating coil 14, wherein the direction of the current flowing in the portion 14-2 and the direction of the current flowing in the portion 14-4 are opposite from each other.

(42) The magnetic material core 13 is preferably arranged on a more upstream side in the transporting direction of the workpiece 12 than the third portion 14-3 which is arranged surrounding the circumference of the general potion 12b of the workpiece 12, that is, only on the downstream side in the moving direction of the high temperature portion of the workpiece 12. This is because: if the magnetic material core 13 is arranged on a more downstream side in the transporting direction of the workpiece 12 than the third portion 14-3, that is, the upstream side in the moving direction of the high temperature portion of the workpiece 12, a cooling starting position of the workpiece 12 to be cooled by the water-cooling apparatus 6 of the processing apparatus 0 becomes farther from the induction heating coil 14 by a degree that the magnetic material core 13 is arranged on the downstream side in the transporting direction of the workpiece 12, whereby the heating width of the general portion 12b where the outward flange 12a is excluded becomes larger.

(43) FIG. 2 includes an explanation diagram showing the principle of heating the outward flange 12a by the present invention. FIG. 2A is a view of the magnetic material core 13 and the induction heating coil 14 seen from a direction shown by the arrow D in FIG. 1A, and FIG. 2B is a view of the magnetic material core 13 and the induction heating coil 14 seen from a direction shown by the arrow A in FIG. 1A.

(44) The reason why the outward flange 12a can be heated by the present invention is as follows. As shown in FIG. 2A, the direction of the coil current flowing in the second portion 14-2 of the induction heating coil 14 and the direction of the coil current flowing in the fourth portion 14-4 of the induction heating coil 14 are opposite from each other. Therefore, magnetic fluxes B1 and B2 (shown by void arrows in FIG. 2A) generated to the magnetic material core 13 are mutually intensified. By the magnetic material core 13, the fluxes B1 and B2 are induced so as to penetrate the outward flange 12a.

(45) Accordingly, the fluxes B1 and B2 vertically enter the outward flange 12a, whereby an eddy current X is generated at the outward flange 12a as shown in FIG. 2B. In this case, the flowing direction of the eddy current X is same at the adverse side 12a-1 of the outward flange 12a and at the reverse side 12b-1. Therefore, the cancellation of the eddy current as shown in FIG. 13b does not occur, whereby it is possible to heat the outward flange 12a.

(46) It is most preferable that the fluxes B1 and B2 to be induced by the magnetic material core 13 vertically enter the outward flange 12a (90 of incident angle) . The fluxes B1 and B2 need to have at least an incident angle which enables the fluxes B1 and B2 to penetrate the outward flange 12a, and the incident angle is preferably 30 or more.

(47) As described above, it is possible to heat the outward flange 12a by the present invention. Also the present invention does not use a high frequency induction heating coil having a shape offsetting to both sides in the axial direction of the workpiece 12 along the outward flange 12a as the invention disclosed in Patent Literature 2. In the present invention, in order to arrange the magnetic material core 13 on the upstream side in the transporting direction of the workpiece 12, the induction heating coil 14 is arranged offsetting only to the upstream side in the transporting direction of the workpiece 12. Therefore, the increase amount of the heating width in the present invention is a half or less of that of the invention disclosed in Patent Literature 2 wherein the induction heating coil 14 is arranged offsetting to both sides in the transporting direction of the workpiece 12. Thus, the high frequency induction heating coil 11 is extremely suitable for heating the workpiece 12 in 3DQ.

(48) The effect of the high frequency induction heating coil 11 was confirmed by a numerical analysis simulation. In the numerical analysis simulation, the distribution of heat generation amount in the induction heating was calculated by means of electromagnetic field analysis. From the obtained distribution of heat generation amount, a heat transfer analysis was carried out, whereby the temperature distribution of a hollow workpiece 12 consisting of a steel sheet having a thickness of 1 mm was calculated. The calculation was carried out under the conditions with which the center portion of the base of the general portion 12b of the workpiece 12 has a temperature of 1050 C., as a heating condition of the numerical analysis.

(49) Firstly, the calculation result of the relationship between the current frequency of the high frequency induction heating coil 5 and the temperature of the outward flange 9a in a case where the conventional high frequency induction heating coil 5 shown in FIGS. 12A and 12B was used is shown by the graph in FIG. 3A. Here, the temperature of the outward flange 9a is a temperature at an end portion of the outward flange 9a. Also, the electric power required to heat the center portion of the base of the general portion 9b of the workpiece 9 to 1050 C. is shown by the graph in FIG. 3B.

(50) As shown by the graph in FIG. 3A, in a case where the conventional high frequency induction heating apparatus 5 was used, the current frequency of the high frequency induction heating coil 5 was needed to be increased to 300 kHz or more in order to heat the outward flange 9a to 900 C. or more. Also, as shown by the graph in FIG. 3B, the required electric power increased as the frequency increased. For example, only 100 kW of electric power was required when a power source of 10 kHz was used; however 225 kW of electric power was required when a power source of 300 kHz was used. The reason for the increase in the electric power consumption as the frequency of the current of the high frequency induction heating apparatus 5 increases is that the number of alternation of the magnetic field per unit time increases as the frequency increases. Here, if the magnetic field is generated only at the workpiece 9 and all the energy which alternates the magnetic field is consumed for heating, the electric power consumption does not largely increase. However, the high frequency induction heating apparatus 5 generates the magnetic field not only to the workpiece 9 but also to the surrounding open space. Even though the magnetic field generated to the open space is not related to the heating, it alternates the magnetic field in the open space to thereby consume energy. Therefore, electric power consumption largely increases.

(51) FIG. 4 includes a graph showing the calculation results by a numerical analysis in a case where the high frequency induction heating apparatus 11 according to the present invention shown in FIGS. 1A to 10 was used. FIG. 4A shows the relationship between the length of the magnetic material core 13 in the longitudinal direction of the workpiece 12 (core length) and the temperature of the outward flange 12a. FIG. 4B shows the relationship between the core length and the electric power consumption. Here, the frequency of the current carried to the high frequency induction coil 11 was 10 kHz, and the transporting speed of the workpiece 12 was 80 mm/s.

(52) As shown by the graph in FIG. 4A, the outward flange 12a became easier to be heated as the core length became longer. The core length 0 mm in the graph in FIG. 4A shows a case where the magnetic material core 13 was not used and the outward flange 12a was heated by means of the conventional high frequency induction heating apparatus 5. In this case, the outward flange 12a was heated only to approximately 580 C.

(53) In order to carry out the high frequency quenching to the workpiece 12, the workpiece 12 needs to be heated to 900 C. or more. On the other hand, if the workpiece 12 is heated to more than 1200 C., enlargement and oxidation of crystal grains are progressed, whereby the surface of the bending member to be manufactured by 3DQ becomes rough. Therefore, the heating temperature of the workpiece 12 is adequate within a range of 900 C. and 1200 C.

(54) Here, it is shown from the graph in FIG. 4A that, in order to heat the outward flange 12a of the workpiece 12 to 900 C. or more and 1200 C. or less, the core length of the magnetic material core 13 can be set as 19.9 mm or more and 30.7 mm or less. Also, from the graph in FIG. 4B, it is shown that: the electric power consumption was 105 kW in a case where the magnetic material core 13 was not used (in a case where the core length was 0 mm) ; whereas the electric power consumption was 140 kW in a case where the core length of the magnetic material core 13 which can heat the workpiece 12 to 900 C. was set for example as 20 mm. Compared with the fact that the electric power consumption was 225 kW in a case where the normal induction heating coil 5 was used to heat the outward flange 12a to 900 C. with 300 kHz of frequency, the electric power consumption by means of the high frequency induction heating coil 11 was smaller by approximately 80 kW.

(55) As shown by the graph in FIG. 3A, the outward flange 12a becomes easier to be heated as the frequency of the current of the high frequency induction heating coil 11 increases. Therefore, as the frequency of the current of the high frequency induction heating coil 11 increases, it is possible to shorten the core length of the magnetic material core 13.

(56) FIG. 5 is a graph showing the relationship between the core length of the magnetic material core 13 and the heating temperature of the outward flange 12a in a case where the frequency of the current of the high frequency induction heating coil 11 was set as 50 kHz.

(57) In this case, in order to heat the outward flange 12a from 900 C. to 1200 C., the core length of the magnetic material core 13 can be set as 3.4 mm or more and 7.5 mm or less.

(58) In the same way, the graph in FIG. 6 shows the relationship between the core length of the magnetic material core 13 and the heating temperature of the outward flange 12a in a case where the frequency of the current of the high frequency induction heating coil 11 was set as 100 kHz. In a case where the current frequency of the high frequency induction heating coil 11 is 100 kHz or more, the core length of the magnetic material core 13 can be set as 1.2 mm or more and 4.3 mm or less.

(59) As described above, as the frequency of the current of the high frequency induction heating coil 11 is higher and the core length of the magnetic material core 13 is longer, the heating temperature of the outward flange 12a becomes higher. Table 1 collectively shows a relationship between the core length of the magnetic material core 13 and the frequency of the current of the high frequency induction heating coil 11 to heat the outward flange 12a to 900 C. or more and 1200 C. or less, in a case where the transporting speed of the workpiece 12 was 80 mm/s.

(60) TABLE-US-00001 TABLE 1 Frequency f (kHz) Core length L (mm) 10 19.9~30.7 50 3.4~7.5 100 1.2~4.3

(61) Table 1 shows the results in a case where the transporting speed of the workpiece 12 was 80 mm/s. However, the adequate core length of the magnetic material core 13 changes depending on the transporting speed of the workpiece 12. Table 2 collectively shows the relationship between the core length of the magnetic material core 13 and the frequency of the current of the high frequency induction heating coil 11 to heat the outward flange 12a to 900 C. or more and 1200 C. or less, in a case where the transporting speed of the workpiece 12 was 20 mm/s. Table 3 collectively shows the relationship between the core length of the magnetic material core 13 and the frequency of the current of the high frequency induction heating coil 11 to heat the outward flange 12a to 900 C. or more and 1200 C. or less, in a case where the transporting speed of the workpiece 12 was 160 mm/s.

(62) TABLE-US-00002 TABLE 2 Frequency f (kHz) Core length L (mm) 10 10.1~16.7 50 2.6~5.0 100 1.1~3.4

(63) TABLE-US-00003 TABLE 3 Frequency f (kHz) Core length L (mm) 10 25.9~43.8 50 4.0~10.2 100 1.2~5.2

(64) FIG. 7 is a graph showing the results of sorting out the minimum value of the adequate core length of the magnetic material core 13 shown in Tables 1 to 3. In the same way, FIG. 8 is a graph showing the results of sorting out the maximum value of the adequate core length of the magnetic material core 13.

(65) As shown by the graphs in FIGS. 7 and 8 , both the minimum value and the maximum value of the adequate core length of the magnetic material core 13 were approximated by the power of the transporting speed V of the workpiece 12. From the graphs in FIGS. 7 and 8, the adequate length L (mm) of the magnetic material core 13 can be obtained as a.sub.minV.sup.1/2<L<a.sub.maxV.sup.1/2.

(66) Next, FIG. 9 is a graph showing the examination results of the frequency dependence of the coefficient a in FIGS. 7 and 8.

(67) As shown by the graph in FIG. 9, it became clear that the coefficient a depends on the inverse number of the frequency f (kHz) of the current of the high frequency induction heating coil.

(68) From the above, in order to adequately set the core length of the magnetic material core 13, it is desirable to satisfy the following Formula 1, wherein L (mm) is the length of the magnetic material core 13 in the longitudinal direction of the workpiece 12, f (kHz) is the frequency of the current of the high frequency induction heating coil 11, and v (mm/s) is the moving speed of the high temperature portion in the workpiece 12 (transporting speed of the workpiece 12).

(69) $\begin{array}{cc}\frac{21}{f}\sqrt{V}<L<\frac{35}{f}\sqrt{V}& \left(1\right)\end{array}$

(70) FIG. 10 includes an explanation diagram showing the temperature distribution in the circumference direction of the workpieces 12 and 9, in a case where the workpieces 12 and 9 were heated by means of the high frequency induction heating coils 11 and 5. FIG. 10A shows an example of the present invention, and FIG. 10B shows a conventional example.

(71) In a case where the present invention was applied, the core length of the magnetic material core 13 was predicted as 1.9 mm or more and 3.1 mm or less, and the length of the magnetic material core was 3 mm.

(72) As shown in FIGS. 10A and 10B, each temperature of the workpieces 12 and 9 in Example and Comparative Example was equally 1050 C.; however, it was shown that the temperature of the outward flange 9a of Comparative Example was less than 900 C. whereas the temperature of the outward flange 12a of Example was heated to 900 C. or more.

(73) By employing the high frequency induction heating apparatus 10 explained above in place of the high frequency induction heating apparatus 5 of the processing apparatus 0 shown in FIG. 11, it is possible to provide a processing apparatus having the above-mentioned effects.

DESCRIPTION OF REFERENCE NUMERALS

(74) 10 high frequency induction heating apparatus 11 high frequency induction heating coil 12 workpiece 12a outward flange 12a-1, 12a-2 face 12b general portion 13 magnetic material core 13-1, 13-2 portion parallel to outward flange 14 induction heating coil 14-1 to 14-5 first portion to fifth portion