Energization cycle counter for induction heating tool

• US 20050145621A1
• Filed: 10/26/2004
• Published: 07/07/2005
• Est. Priority Date: 01/02/2004
• Status: Active Grant

• Current Assignee: Ajax Tocco Magnethermic Corporation (Park-Ohio Holdings Corporation)
• Original Assignee: Kathleen M. Bartz
• Inventors: Bartz, Kathleen M.
• Granted Patent: US 7,041,946 B2
• Time in Patent Office: Days
• US Class Current: 219/663
• CPC Class Codes: H05B 6/06 Control, e.g. of temperature, of power

Abstract

An induction heat treating process with a remote sensor for monitoring the duration of energization of an induction heating coil each time the induction heating coil is consecutively cycled. An identifying tag is preferably attached to, embedded within the induction heating coil or within the surrounding area of the induction coil and transmits a signal to a remote counting sensor that is preferably triggered by and responds to the change in voltage generated as the coil is energized. Alternative means of measuring a cycle may be implemented. The output data from the sensor provides useful information for determining the lifespan of an induction heating coil. Predicting the lifespan of a coil optimizes production by anticipating failure and replacement of a coil during a predetermined down time, limiting on-site inventory, and revolutionizing the billing cycle based on a per cycle cost while decreasing overall production costs and improving inductor coil quality.

Claims

1. A method of monitoring the duration of energization attributable to an induction heating coil comprising the steps of:

providing an induction heating coil with an identifying tag and remote counting sensor for monitoring the duration of energization of the induction heating coil;

generating a magnetic field about said induction heating coil; and

triggering said remote counting sensor to increase the count in response to said magnetic field and begin measuring the time interval of said duration of energization.

2. The method of claim 1, wherein said remote counting sensor comprises a sensor for receiving and outputting counting data, said data including the measurement of a time interval for the measured duration of energization period of said induction heating coil.

3. The method of claim 2, wherein said identifying tag is removably attached to said induction heating coil.

4. The method of claim 2, wherein said identifying tag is embedded within said induction heating coil.

5. The method of claim 2, wherein said identifying tag is located within a triggerable area of the induction heating coil.

6. The method of claim 2, and further comprising the step of:

said remote counting sensor monitoring the duration of energization of the induction heating coil each time said identifying tag is triggered.

7. The method of claim 2, and further comprising the step of:

reading said counting data from said remote counting sensor.

8. The method of claim 6, and further comprising the step of:

reading said counting data from said remote counting sensor.

9. The method of claim 1, wherein said identifying tag is an identifier of said induction heating coil, and further comprising the step of:

said identifier emitting a signal for triggering said remote counting sensor to monitor the duration of energization of the induction heating coil each time said induction heating coil is cycled.

10. The method of claim 9, and further comprising the step of:

reading said counting data from said remote counting sensor.

11. A method of monitoring the duration of energization per cycle attributable to an induction heating coil of an induction heating coil assembly, said assembly comprising a power supply and an induction heating coil subassembly including said induction heating coil and a bus bar connecting said coil to said power supply, the method comprising the steps of:

providing an induction heating coil subassembly with an identifying tag and remote counting sensor;

wherein said identifying tag is an identifier of said induction heating coil and wherein said remote counting sensor comprises a sensor for receiving and outputting counting data;

generating a magnetic field about said coil;

triggering said remote counting sensor when said magnetic field is generated;

said identifying tag emitting a signal for triggering said remote counting sensor to monitor the duration of energization of the induction heating coil each time said induction heating coil is cycled, wherein said remote counting sensor monitors the duration of energization of the induction heating coil each time said induction heating coil is cycled when said magnetic field is generated about said coil;

maintaining said coil within said induction heating coil subassembly and continuing to monitor the duration of energization of the induction heating coil each time said induction heating coil is consecutively cycled until said coil fails;

reading said output data of said remote counting sensor;

wherein said output data includes the measurement of a time interval for the measured duration of energization period sustained by said coil; and

establishing a baseline lifespan for said coil based on said output data.

12. The method of claim 11, and further comprising the steps of:

providing a series of like induction heating coil subassemblies each with said identifying tag and remote counting sensor;

generating a magnetic field about each coil of said induction heating coil subassemblies;

triggering each of said remote counting sensors when said magnetic field is generated, said identifying tag emitting a signal for triggering said remote counting sensor;

maintaining each of said coils within said induction heating coil subassemblies and continuing to monitor the duration of energization of each of said induction heating coils each time said induction heating coil is consecutively cycled until each of said coil fails;

reading said output data of each said remote counting sensors;

wherein said output data includes the measurement of a time interval for the measured duration of energization period sustained by said coils; and

establishing an average baseline lifespan for said like coils based on said output data.

13. The method of claim 11, and further comprising the step of:

replacing said coil with a new coil upon said failure.

14. The method of claim 12, and further comprising the steps of:

once said average baseline lifespan is established for said like coils, replacing at least one of said coils with a new like coil upon said failure, wherein said new coil comprises an identifying tag and remote counting sensor for receiving and outputting counting data;

monitoring said duration of energization for each time said induction heating coil is consecutively cycled and sustained by said replaced coil by reading said output data; and

recommending replacing said replaced coil prior to failure of said coil if said measurement of a time interval for the measured duration of energization period is within a pre-determined range of said average baseline lifespan for said like coils.

15. The method of claim 11, wherein said identifying tag is removably attached to said induction heating coil.

16. The method of claim 11, wherein said identifying tag is embedded within said induction heating coil.

17. The method of claim 11, wherein said identifying tag is located within a triggerable area of the induction heating coil.

18. The method of claim 14, further comprising the step of:

replacing said replaced coil with a new coil having an identifying tag and remote counting sensor for receiving and outputting counting data.

43. The method of claim 15, further comprising the step of:

replacing said replaced coil with a new coil having an identifying tag and remote counting sensor including a sensor for receiving and outputting counting data.

19. A method of monitoring the duration of energization per cycle attributable to an induction heating coil of an induction heating coil assembly comprising a power supply and an induction heating coil subassembly comprising said induction heating coil and a bus bar connecting said induction heating coil to said power supply, wherein an average baseline lifespan for said induction heating coil has been established, the method comprising the steps of:

providing said induction heating coil subassembly with an identifying tag and remote counting sensor;

wherein said identifying tag is an identifier of said induction heating coil and wherein said remote counting sensor comprises a sensor for receiving and outputting counting data;

generating a magnetic field about said coil;

triggering said remote counting sensor when said magnetic field is generated;

said identifying tag emitting a signal for triggering said remote counting sensor, wherein said remote counting sensor monitors the duration of energization of the induction heating coil each time said induction heating coil is cycled when said magnetic field is generated about said coil;

reading said output data of said remote counting sensor;

wherein said output data includes the measurement of a time interval for the measured duration of energization period sustained by said coil;

monitoring said duration of energization for each time said induction heating coil is consecutively cycled and sustained by said replaced coil by reading said output data; and

recommending replacing said replaced coil prior to failure of said coil if said measurement of a time interval for the measured duration of energization period is within a pre-determined range of said average baseline lifespan for said like coils.

20. The method of claim 19, wherein said identifying tag is removably attached to said induction heating coil.

21. The method of claim 19, wherein said identifying tag is embedded within said induction heating coil.

22. The method of claim 19, wherein said identifying tag is located within a triggerable area of the induction heating coil.

23. The method of claim 19, wherein said remote counting sensor is triggered by a change in voltage across said induction heating coil subassembly when said power supply is activated.

24. The method of claim 19, wherein said remote counting sensor is triggered by any one of the following events when said magnetic field is generated about said induction heating coil:

a temperature differential, a current flow differential, a frequency differential, or a magnetic field differential causing a Hall effect.

25. The method of claim 19, further comprising the step of:

replacing said replaced coil with a new coil having a remote counting sensor including a sensor for receiving and outputting counting data.

26. A method for monitoring the amount of cycles attributable to an induction coil comprising the steps of:

providing an induction coil with an identifying tag and remote counting sensor;

generating a magnetic field about said induction coil ; and

triggering said remote counting sensor when said magnetic field is generated.

27. The method of claim 26, wherein said remote counting sensor comprises a sensor for receiving and outputting counting data.

28. The method of claim 27, wherein said identifying tag is removably attached to said induction heating coil.

29. The method of claim 27, wherein said identifying tag is embedded within said induction heating coil.

30. The method of claim 27, wherein said identifying tag is located within a triggerable area of the induction heating coil.

31. The method of claim 27, and further comprising the step of:

said remote counting sensor consecutively counting each time said sensor is triggered.

32. The method of claim 27, and further comprising the step of:

reading said counting data from said remote counting sensor.

33. The method of claim 31, and further comprising the step of:

reading said counting data from said remote counting sensor.

34. The method of claim 26, wherein said identifying tag is an identifier of said induction heating coil, and further comprising the step of:

said identifier emitting a signal for triggering said remote counting sensor each time said induction coil is cycled.

35. The method of claim 34, reading said counting data from said remote counting sensor.

36. A method for monitoring the amount of cycles attributable to an induction coil of an induction coil assembly, said assembly comprising a power supply and an induction coil subassembly including said induction coil and a bus bar connecting said coil to said power supply, the method comprising the steps of:

providing an induction heating coil subassembly with an identifying tag and remote counting sensor;

wherein said identifying tag is an identifier of said induction heating coil and wherein said remote counting sensor comprises a sensor for receiving and outputting counting data;

generating a magnetic field about said coil;

triggering said remote counting sensor when said magnetic field is generated;

said identifying tag emitting a signal for triggering said remote counting sensor consecutively counts a cycle each time said magnetic field is generated about said coil;

maintaining said coil within said induction coil subassembly and continuing to consecutively count said cycles until said coil fails;

reading said output data of said remote counting sensor;

wherein said output data includes the total amount of consecutive cycles sustained by said coil; and

establishing a baseline lifespan for said coil based on said output data.

37. The method of claim 36, and further comprising the steps of:

providing a series of like induction coil subassemblies each with said remote counting sensor;

generating a magnetic field about each coil of said induction coil subassemblies;

triggering each of said remote counting sensors when said magnetic field is generated;

maintaining each of said coils within said induction coil subassemblies and continuing to consecutively count said cycles until each of said coil fails;

reading said output data of each said remote counting sensors;

wherein said output data includes the total amount of consecutive cycles sustained by each of said coils; and

establishing an average baseline lifespan for said like coils based on said output data.

38. The method of claim 36, and further comprising the step of:

replacing said coil with a new coil upon said failure.

39. The method of claim 37, and further comprising the steps of:

once said average baseline lifespan is established for said like coils, replacing at least one of said coils with a new like coil upon said failure, wherein said new coil comprises an identifying tag and remote counting sensor for receiving and outputting counting data;

monitoring said consecutive cycles sustained by said replaced coil by reading said output data; and

recommending replacing said replaced coil prior to failure of said coil if said cycles are within a pre-determined range of said average baseline lifespan for said like coils.

40. The method of claim 36, wherein said identifying tag is removably attached to said induction heating coil.

41. The method of claim 36, wherein said identifying tag is embedded within said induction heating coil.

42. The method of claim 36, wherein said identifying tag is located within a triggerable area of the induction heating coil.

44. A method for monitoring the amount of cycles attributable to an induction coil of an induction coil assembly comprising a power supply and an induction coil subassembly comprising said induction coil and a bus bar connecting said induction coil to said power supply, wherein an average baseline lifespan for said induction coil has been established, the method comprising the steps of:

providing said induction coil subassembly with an identifying tag and remote counting sensor;

wherein said counting mechanism comprises a sensor for receiving and outputting counting data;

generating a magnetic field about said coil triggering said remote counting sensor when said magnetic field is generated;

wherein said remote counting sensor consecutively counts a cycle each time said magnetic field is generated about said coil;

reading said output data of said remote counting sensor;

wherein said output data includes the total amount of consecutive cycles sustained by said coil;

monitoring said consecutive cycles sustained by said coil by reading said output data; and

recommending replacing said coil prior to failure of said coil if said cycles are within a pre-determined range of said average baseline lifespan for said like coils.

45. The method of claim 44, wherein said identifying tag is removably attached to said induction heating coil.

46. The method of claim 44, wherein said identifying tag is embedded within said induction heating coil.

47. The method of claim 44, wherein said identifying tag is located within a triggerable area of the induction heating coil.

48. The method of claim 44, wherein said remote counting sensor is triggered by a change in voltage across said induction coil subassembly when said power supply is activated.

49. The method of claim 44, wherein said remote counting sensor is triggered by any one of the following events when said magnetic field is generated about said induction coil:

a temperature differential, a current flow differential, a frequency differential, or a magnetic field differential causing a Hall effect.

50. The method of claim 44, further comprising the step of:

replacing said replaced coil with a new coil having an identifying tag and remote counting sensor for receiving and outputting counting data.