Hybrid induction heating/welding assembly

{
  "publication_number": "US10244588B2",
  "country": "US",
  "kind": "B2",
  "title": "Hybrid induction heating/welding assembly",
  "abstract": "In certain embodiments, inductive heating is added to a metal working process, such as a welding process, by an induction heating head. The induction heating head may be adapted specifically for this purpose, and may include one or more coils to direct and place the inductive energy, protective structures, and so forth. Productivity of a welding process may be improved by the application of heat from the induction heating head. The heating is in addition to heat from a welding arc, and may facilitate application of welding wire electrode materials into narrow grooves and gaps, as well as make the processes more amenable to the use of certain compositions of welding wire, shielding gasses, flux materials, and so forth. In addition, distortion and stresses are reduced by the application of the induction heating energy in addition to the welding arc source.",
  "claims": [
    "1. A hybrid induction heating/welding assembly comprising: a protective outer housing; a metal working tool configured to perform a metal working process on at least one workpiece, wherein the metal forming tool is at least partially enclosed within the protective outer housing; at least one induction heating coil configured to apply induction heat to the at least one workpiece, wherein the at least one induction heating coil is disposed proximate the metal forming tool, and wherein the at least one induction heating coil is at least partially enclosed within the protective outer housing; and a mechanical motion system configured to control position, orientation, or movement of the protective outer housing, the at least partially enclosed metal working tool, and the at least partially enclosed at least one induction heating coil relative to the at least one workpiece.",
    "2. The hybrid induction heating/welding assembly of claim 1, comprising a flux concentrator material at least partially disposed around the at least one induction heating coil.",
    "3. The hybrid induction heating/welding assembly of claim 1, wherein the metal working tool comprises a welding torch.",
    "4. The hybrid induction heating/welding assembly of claim 1, wherein the metal working tool comprising a plasma cutting torch.",
    "5. The hybrid induction heating/welding assembly of claim 1, comprising a spray head configured to deliver a coolant to a surface of the at least one workpiece.",
    "6. The hybrid induction heating/welding assembly of claim 5, wherein the coolant comprises water.",
    "7. The hybrid induction heating/welding assembly of claim 5, comprising an air knife configured to direct a curtain of air to the surface of the at least one workpiece to maintain a relatively dry spot on the at least one workpiece to facilitate induction heating of the at least one workpiece by the at least one induction heating coil.",
    "8. The hybrid induction heating/welding assembly of claim 7, wherein the air knife comprises a circular air knife.",
    "9. The hybrid induction heating/welding assembly of claim 7, wherein the air knife comprises a frustoconical air knife.",
    "10. The hybrid induction heating/welding assembly of claim 1, comprising at least one laser height sensor disposed within the protective outer housing and configured to detect a distance relating to a distance of the at least one induction heating coil from a surface of the at least one workpiece.",
    "11. The hybrid induction heating/welding assembly of claim 10, comprising a laser height sensor module disposed within the protective outer housing, communicatively coupled to the at least one laser height sensor, and configured to determine the distance of the at least one induction heating coil from the surface of the at least one workpiece.",
    "12. The hybrid induction heating/welding assembly of claim 1, comprising an infrared temperature sensor module disposed within the protective outer housing and configured to determine at least one temperature proximate the at least one induction heating coil or a surface of the at least one workpiece.",
    "13. The hybrid induction heating/welding assembly of claim 1, comprising a compressed air manifold disposed within the protective outer housing and configured to deliver compressed air to a surface of the at least one workpiece.",
    "14. The hybrid induction heating/welding assembly of claim 13, comprising one or more air valves disposed within the protective outer housing and configured to control flow rates of one or more air streams delivered to the surface of the at least one workpiece.",
    "15. The hybrid induction heating/welding assembly of claim 14, comprising one or more air flow sensors disposed within the protective outer housing and configured to detect the flow rates of the one or more air streams delivered to the surface of the at least one workpiece.",
    "16. The hybrid induction heating/welding assembly of claim 1, comprising a water manifold disposed within the protective outer housing and configured to deliver water to a surface of the at least one workpiece.",
    "17. The hybrid induction heating/welding assembly of claim 16, comprising one or more water flow sensors disposed within the protective outer housing and configured to detect flow rates of one or more water flow streams delivered to the surface of the at least one workpiece.",
    "18. The hybrid induction heating/welding assembly of claim 16, comprising one or more water temperature sensors disposed within the protective outer housing and configured to detect temperatures of one or more water flow streams delivered to the surface of the at least one workpiece.",
    "19. The hybrid induction heating/welding assembly of claim 1, wherein the protective outer housing comprises high density polypropylene, ceramic, plexiglass, or some combination thereof.",
    "20. The hybrid induction heating/welding assembly of claim 1, comprising an access cover configured to facilitate access to internal components of the hybrid induction heating/welding assembly.",
    "21. The hybrid induction heating/welding assembly of claim 1, comprising a motorized mount configured to mount the hybrid induction heating/welding assembly to the mechanical motion system.",
    "22. A hybrid induction heating/welding assembly comprising: a protective outer housing; a metal working tool configured to perform a metal working process on at least one workpiece, wherein the metal forming tool is at least partially enclosed within the protective outer housing; at least one induction heating coil configured to apply induction heat to the at least one workpiece, wherein the at least one induction heating coil is disposed proximate the metal forming tool, and wherein the at least one induction heating coil is at least partially enclosed within the protective outer housing; and a coil protective housing disposed directly adjacent the at least one induction heating coil and between the metal working tool and the at least one induction heating coil."
  ],
  "description_excerpt": "The present disclosure relates generally to the field of welding systems and processes, and more particularly to welding systems and processes that utilize induction heating as an additional source of heating energy.\n\nProductivity is of high importance in any manufacturing operation. In many manufacturing operations, welding of workpieces is an important and integral part of producing high quality assemblies. A number of welding systems have been used and are being developed, including gas metal arc welding (GMAW), gas tungsten arc welding (GTAW), shielded metal arc welding (SMAW), submerged arc welding (SAW), and so forth. And all of these may be used depending upon such factors as the parts to be joined, the size and thicknesses of the materials, the final assembly desired, and the materials used.\n\nIn some contexts, it has been proposed to utilize secondary heat sources, such as induction heating, in conjunction with welding systems. Such processes are sometimes referred to as “hybrid induction welding” processes. Hybrid induction welding can produce welds at higher speeds, with less pre-weld preparation, and using fewer consumables compared to processes such as arc welding alone. Moreover, supplemental heating can change the cooling rate of the weld, which can improve the quality of the finished weld. All fusion welding processes, where a metal is melted in order to form a weld joint, involve the application of, or generation of, heat in some form. Hybrid induction welding processes add heat from an induction heating head or source which improves the productivity.",
  "cpc": [
    "B23K 9/095",
    "B23K 10/00",
    "B23K 13/01",
    "B23K 13/02",
    "B23K 28/02",
    "B23K 3/0475",
    "B23K 31/003",
    "B23K 37/003",
    "B23K 37/006",
    "B23K 37/0247",
    "B23K 9/02",
    "B23K 9/0213",
    "B23K 9/0953",
    "B23K 9/126",
    "B23K 9/16",
    "B23K 9/173",
    "B23K 9/235",
    "B23K 9/321",
    "B23K 9/322",
    "H05B 11/00"
  ],
  "ipc": [
    "H05B 11/00",
    "B23K 10/00",
    "B23K 13/01",
    "B23K 28/02",
    "B23K 31/00",
    "B23K 9/00",
    "B23K 9/02",
    "B23K 9/095",
    "B23K 9/173",
    "B23K 9/235"
  ],
  "assignees": [
    "Illinois Tool Works Inc"
  ],
  "inventors": [
    "Jerald Edward Jones",
    "Valerie Lisa Rhoades",
    "Todd Earl Holverson",
    "Adam Nathan Cuneo",
    "Mark Dietrich Mann"
  ],
  "filing_date": "2015-10-09",
  "publication_date": "2019-03-26",
  "grant_date": "2019-03-26",
  "priority_date": "2014-10-14",
  "application_number": "US-201514879735-A",
  "family_id": "55656432",
  "cited_by_count": 1,
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}