Patent Description:
Induction heating refers to a method for producing heat in a localized area on a susceptible (typically metal) object. Induction heating involves applying an alternating current (AC) electric signal to a heating loop placed near a specific location on and/or near a piece of metal to be heated. The varying current in the loop creates a varying magnetic flux within the metal to be heated. Current is induced in the metal by the magnetic flux and the internal resistance of the metal causes it to heat up in a relatively short period of time.

Induction heating may be used for many different purposes including curing adhesives, hardening of metals, brazing, soldering, and other fabrication processes in which heat is a necessary or desirable agent. Induction heating may also be used in conjunction with welding systems, such as, for example, for heating materials before, during, and/or after welding.

Limitations and disadvantages of conventional and traditional approaches will become apparent to one of skill in the art, through comparison of such systems with the present disclosure as set forth in the remainder of the present application with reference to the drawings. <CIT> discloses an inductive heating device having a power supply, an inductive coupling assembly, and an inductor core. <CIT> discloses a non-contact power transmission device. <CIT> discloses a plug connection for a hazardous location for energy and data transmission by means of electrical quantities in a bus system. The plug connection has a primary part and a secondary part constructed as transmitters, as well as limiting means for the electrical quantities to be transmitted. <CIT> discloses an inductive coupler for transferring electrical power from the primary to the secondary. <CIT> discloses an underwater connector including a first component and a second component, wherein the components are operable to be coupled together in operation in a first coupled state, and operable to be mutually spatially separated in a second uncoupled state.

The present disclosure is directed to apparatus, systems, and methods for induction heating, for example, substantially as illustrated by and/or described in connection with at least one of the figures, and as set forth more completely in the claims.

These and other advantages, aspects and novel features of the present disclosure, as well as details of an illustrated example thereof, will be more fully understood from the following description and drawings.

Where appropriate, the same or similar reference numerals are used in the figures to refer to similar or identical elements. For example, reference numerals utilizing lettering (e.g., induction heating tool 108a, induction heating tool 108b) refer to instances of the same reference numeral that does not have the lettering (e.g., induction heating tool(s) <NUM>).

Preferred examples of the present disclosure may be described hereinbelow with reference to the accompanying drawings. In the following description, well-known functions or constructions are not described in detail because they may obscure the disclosure in unnecessary detail. For this disclosure, the following terms and definitions shall apply.

As used herein, "and/or" means any one or more of the items in the list joined by "and/or".

As used herein the terms "circuits" and "circuitry" refer to physical electronic or electrical components (i.e., hardware) and any software and/or firmware ("code") which may configure the hardware, be executed by the hardware, and or otherwise be associated with the hardware. As utilized herein, circuitry is "operable" and/or "configured" to perform a function whenever the circuitry comprises the necessary hardware and/or code (if any is necessary) to perform the function, regardless of whether performance of the function is disabled or enabled (e.g., by a user-configurable setting, factory trim, etc.).

As used herein, a control circuit may include digital and/or analog circuitry, discrete and/or integrated circuitry, microprocessors, DSPs, etc., software, hardware and/or firmware, located on one or more boards, that form part or all of a controller, and/or are used to control a welding process, and/or a device such as a power source or wire feeder.

As used herein, the term "processor" means processing devices, apparatus, programs, circuits, components, systems, and subsystems, whether implemented in hardware, tangibly embodied software, or both, and whether or not it is programmable. The term "processor" as used herein includes, but is not limited to, one or more computing devices, hardwired circuits, signal-modifying devices and systems, devices and machines for controlling systems, central processing units, programmable devices and systems, field-programmable gate arrays, application-specific integrated circuits, systems on a chip, systems comprising discrete elements and/or circuits, state machines, virtual machines, data processors, processing facilities, and combinations of any of the foregoing. The processor may be, for example, any type of general purpose microprocessor or microcontroller, a digital signal processing (DSP) processor, an application-specific integrated circuit (ASIC). The processor may be coupled to, and/or integrated with a memory device.

As used, herein, the term "memory" and/or "memory device" means computer hardware or circuitry to store information for use by a processor and/or other digital device. The memory and/or memory device can be any suitable type of computer memory or any other type of electronic storage medium, such as, for example, read-only memory (ROM), random access memory (RAM), cache memory, compact disc read-only memory (CDROM), electro-optical memory, magneto-optical memory, programmable read-only memory (PROM), erasable programmable read-only memory (EPROM), electrically-erasable programmable read-only memory (EEPROM), a computer-readable medium, or the like.

The term "power" is used throughout this specification for convenience, but also includes related measures such as energy, current, voltage, and enthalpy. For example, controlling "power" may involve controlling voltage, current, energy, and/or enthalpy, and/or controlling based on "power" may involve controlling based on voltage, current, energy, and/or enthalpy.

As used herein, a welding-type power supply and/or power source refers to any device capable of, when power is applied thereto, supplying welding, cladding, plasma cutting, induction heating, laser (including laser welding, laser hybrid, and laser cladding), carbon arc cutting or gouging and/or resistive preheating, including but not limited to transformer-rectifiers, inverters, converters, resonant power supplies, quasi-resonant power supplies, switch-mode power supplies, etc., as well as control circuitry and other ancillary circuitry associated therewith.

As used herein, welding-type power refers to power suitable for welding, cladding, plasma cutting, induction heating, CAC-A and/or hot wire welding/preheating (including laser welding and laser cladding), carbon arc cutting or gouging, and/or resistive preheating.

As used herein, an induction heating system includes a power source that can provide power for induction heating, such as, for example, via an induction heating tool that can induce heat in a workpiece.

As used herein, an induction heating power supply refers to a power supply that is capable of providing induction-type power to an induction heating tool, induction heating element, induction heating coil, and/or induction heating head, to induce current flow and/or heat in a (typically metallic) workpiece.

As used herein, induction-type power refers to power suitable for an induction heating tool, induction heating element, induction heating coil, and/or induction heating head, to induce current flow and/or heat in a (typically metallic) workpiece.

As used herein, an induction heating tool refers to an inductive load such as an induction heating coil, an induction heating winding, and/or an induction heating coil, which heats a workpiece by induction.

As used herein, a winding refers to conductor that induces a magnetic field when current flows therein.

As used herein, the terms "coupled," "coupled to," and "coupled with," each mean a structural and/or electrical connection, whether attached, affixed, connected, joined, fastened, linked, and/or otherwise secured. As used herein, the term "attach" means to affix, couple, connect, join, fasten, link, and/or otherwise secure. As used herein, the term "connect" means to attach, affix, couple, join, fasten, link, and/or otherwise secure.

As used herein, the terms "about" and/or "approximately," when used to modify or describe a value (or range of values), position, orientation, and/or action, mean reasonably close to that value, range of values, position, orientation, and/or action. Thus, the examples described herein are not limited to only the recited values, ranges of values, positions, orientations, and/or actions but rather should include reasonably workable deviations.

Some examples of the present disclosure relate to an induction heating system, comprising a first power coupler comprising a first magnetic core, the first power coupler configured for electrical communication with an induction heating power supply, and a second power coupler comprising a second magnetic core, the second power coupler configured for electrical communication with an induction heating tool, where the first power coupler and second power coupler are configured to magnetically couple the first magnetic core and the second magnetic core to form a transformer through which the induction heating power is transferred to the induction heating tool.

In some examples, the first power coupler is configured for releasable attachment to the induction heating power supply. In some examples, the second power coupler is configured for releasable attachment to the induction heating tool. In some examples, the first power coupler further comprises a first winding wound around the first magnetic core and the second power coupler further comprises a second winding wound around the second magnetic core. In some examples, the first winding is hermetically sealed within a first housing that retains the first magnetic core, the second winding is hermetically sealed within a second housing that retains the second magnetic core, and the first and second housings are configured to align the first core with the second core when the first and second power couplers are connected together. In some examples, the first power coupler and the second power coupler are further configured to disconnect to decouple the magnetic coupling between the first magnetic core and the second magnetic core. In some examples, the induction heating power supply is configured to disable when the first power coupler and second power coupler are decoupled. In some examples, the system further comprises control circuitry configured to detect when the first power coupler and second power coupler are decoupled, and the control circuitry is configured to disable the induction heating power supply in response to the detection.

Some examples which are not part of the claimed invention of the present disclosure relate to a method of impedance matching an induction heating power supply, comprising decoupling a first power coupler in electrical communication with an induction heating power supply from a second power coupler in electrical communication with an induction heating tool, the first power coupler comprising a first magnetic core and the second power coupler comprising a second magnetic core, where the first power coupler and second power coupler are configured to magnetically couple the first magnetic core and the second magnetic core to form a transformer through which induction heating power is transferred from the induction power supply to the induction heating tool. The method further comprises coupling the first power coupler to a third power coupler in electrical communication with the induction heating tool or an alternate induction heating tool, the third power coupler comprising a third magnetic core, where the first power coupler and third power coupler are configured to magnetically couple the first magnetic core and the third magnetic core to form a transformer through which the induction heating power is transferred to the induction heating tool or the alternate induction heating tool.

In some examples, the first power coupler further comprises a first winding wound around the first magnetic core, the second power coupler further comprises a second winding wound around the second magnetic core, and the third power coupler further comprises a third winding wound around the third magnetic core. In some examples, the second winding is different than the third winding. In some examples, the second winding comprises a second conductor having a second number of turns and the third winding comprises a third conductor having a third number of turns, where the second number of turns is different than the third number of turns. In some examples, the first winding is hermetically sealed within a first housing that retains the first magnetic core, the second winding is hermetically sealed within a second housing that retains the second magnetic core, the third winding is hermetically sealed within a third housing that retains the third magnetic core, the first and second housings are configured to align the first core with the second core when the first and second power couplers are connected together, and the first and third housings are configured to align the first core with the third core when the first and third power couplers are connected together. In some examples, the method further comprises disabling the induction heating power supply in response to detecting the decoupling of the first power coupler from the second power coupler, and enabling the induction heating power supply in response to detecting the coupling of the first power coupler to the third power.

Some examples of the present disclosure relate to an induction heating power supply, comprising power conversion circuitry configured to receive input power from a power source and convert the input power to induction heating power, and a first power coupler in electrical communication with the power conversion circuitry, the first power coupler comprising a first magnetic core and configured to couple to a second power coupler comprising a second magnetic core, the second power coupler being in electrical communication with an induction heating tool, where the first power coupler and second power coupler are configured to magnetically couple the first magnetic core and the second magnetic core to form a transformer through which the induction heating power is transferred to the induction heating tool.

In some examples, the first power coupler is releasably attached to the induction heating power supply. In some examples, the first power coupler further comprises a first winding wound around the first magnetic core, wherein the first winding is hermetically sealed within a first housing that retains the first magnetic core. In some examples, the first power coupler comprises a power receptacle having an opening configured to receive the second power coupler. In some examples, the first power coupler comprises an insert configured to fit within a receptacle opening of the second power coupler. In some examples, the system further comprises control circuitry configured to disable the power conversion circuitry in response to a signal representative of decoupled first and second power couplers.

Some examples of the present disclosure relate to induction heating systems. In some examples, an induction heating system includes an induction heating power supply and an induction heating tool coupled together through a modular transformer. In some examples, the modular transformer comprises a first coupler (e.g., a power receptacle) and a second coupler (e.g., a power insert) configured to couple together to complete the modular transformer, and/or decouple to separate the modular transformer. In some examples, the first coupler is in electrical communication with the induction heating power supply, and the second coupler is in electrical communication with the induction heating tool. When the first and second couplers are coupled together to complete the modular transformer, induction-type power flows through the modular transformer from the induction heating power supply to the induction heating tool.

Induction heating systems use impedance matching to match the impedance of an induction heating power supply to the impedance of an induction heating tool. Impedance matching increases the efficiency of power transfer from the induction heating power supply to the induction heating tool. One particular strategy for impedance matching is through step up and/or step down transformers.

Conventionally, induction heating systems used one or more hardwired transformers to step up or step down an output voltage, depending on the configuration, needs, and/or impedance of the induction heating tool and/or system. The ratio of the number of primary windings compared to (and/or in proportion to) the number of secondary windings determines the extent to which voltage is stepped up or stepped down. Since conventional induction heating systems use hardwired transformers, an operator must directly access and manipulate exposed conductor wire windings of the transformer in order to manipulate the ratio of primary windings to secondary windings.

Advantageously, the modular transformer contemplated by the present disclosure allows an operator to manipulate the ratio of primary windings to secondary windings without having to directly access and/or manipulate the exposed wire windings of the transformer. In particular, the first coupler comprises a primary set of windings of the modular transformer hermetically sealed within a first housing. The second coupler comprises a secondary set of windings of the modular transformer hermetically sealed within a second housing. If the ratio of primary windings to secondary windings is less than ideal for impedance matching and/or the desired step up/down voltage, an operator can use a different (e.g., third) coupler, with a different number (and/or configuration) of primary/secondary windings, and use that coupler as the first or second coupler of the modular transformer, all without having to directly manipulate any exposed wire windings. In some examples, the induction heating system of the present disclosure may be provided with a plurality of first and/or second couplers, with different windings and/or configurations, that may be swapped in and/or out of the system to allow an operator to manipulate the primary to secondary windings ratio without having to directly access the exposed electrical wires of the transformer.

<FIG> shows an example induction heating system <NUM>, according aspects of the present disclosure. In the example of <FIG>, the induction heating system <NUM> includes an induction heating power supply <NUM> and induction heating tools <NUM> configured to be powered by the power supply <NUM>. As shown, the induction heating power supply <NUM> receives input power from a power source <NUM>. The power source <NUM> is indicated in <FIG> by arrows <NUM>. In some examples, the power source <NUM> may be a generator, battery, main electrical power source, welding-type power supply, etc. In some examples, the power source <NUM> may provide three phase power to the power supply <NUM>. In the example of <FIG>, the induction heating power supply <NUM> is configured to generate AC induction-type power (and/or welding-type power) from the power supplied via the power source <NUM>.

As illustrated in the example of <FIG>, the induction heating power supply <NUM> includes a user interface <NUM>. In some examples, the user interface <NUM> may be a remote interface that communicates with the induction heating power supply <NUM> via a wireless communication channel or a wired cable connection. In some examples, the user interface <NUM> may include input mechanisms, such as buttons, knobs, dials, touch screens, microphones, mice, keyboards, and so forth to allow an operator to regulate various operating parameters of the induction heating power supply <NUM>. For example, the user interface <NUM> may enable an operator to select a particular operation and/or configuration of the induction heating power supply <NUM>, such as a frequency and/or amplitude of the alternating current produced by the induction heating power supply <NUM>, for example. Similarly, the user interface <NUM> may enable an operator to select a desired output temperature of an induction heating tool <NUM> coupled to the induction heating power supply <NUM>. The user interface <NUM> may also include one or more output mechanisms (e.g., display screens and/or audio speakers) configured to provide system feedback to the operator (e.g., temperature and/or travel speed of the induction heating tool <NUM>, etc.). In some examples, the user interface <NUM> may be configured to provide a warning (and/or alert, alarm, feedback, etc.) via the output mechanisms. The warning may be a visual, audio, and/or other type of warning, such as an emphasized visual indication shown on the display screen of the user interface, and/or a klaxon, siren, and/or other sound that may be associated with a warning.

In the example of <FIG>, the induction heating power supply <NUM> includes control circuitry <NUM>. As shown, the control circuitry <NUM> comprises one or more processors <NUM> and memory circuitry <NUM>. In the example of <FIG>, the control circuitry <NUM> further includes instructions and/or circuitry to implement a coupling control process <NUM>, which will be discussed further below. As shown, the control circuitry <NUM> is in electrical communication with the user interface <NUM> and power conversion circuitry <NUM>, further discussed below. The control circuitry <NUM> is further in electrical communication with a power receptacle <NUM>, further discussed below.

In the example of <FIG>, the control circuitry <NUM> is configured to supply control signals to the power conversion circuitry <NUM> to control generation of the induction-type power from the input power provided by the power source <NUM>. For example, the control circuitry <NUM> may provide one or more control signals to the power conversion circuitry <NUM> representative of one or more parameters (e.g., AC frequency and/or amplitude) of the induction-type power generated by the power conversion circuitry <NUM>, and/or a target and/or change in one or more parameters. In such an example, the power conversion circuitry <NUM> may operate and/or adjust its operation according to the control signal(s).

In some examples, the control circuitry <NUM> my use input provided via the user interface <NUM> and/or feedback from the power conversion circuitry <NUM> and/or power receptacle <NUM> when determining the appropriate control signals. For example, the user interface <NUM> may communicate an operator selection to the control circuitry <NUM>, which may process the selection (e.g., via processor <NUM>) and/or retrieve the particular configuration parameters associated with the selection stored in the memory circuitry <NUM>. Thereafter, the control circuitry <NUM> may send one or more control signals representative of the configuration parameters (and/or configured to produce induction-type power with the configuration parameters) to the power conversion circuitry <NUM>.

In some examples, the control circuitry <NUM> is configured to detect characteristics (e.g., voltage, current, resonance, etc.) of the induction-type power provided by the power conversion circuitry <NUM>, such as via one or more feedback signals, for example. In some examples, the control circuitry <NUM> may determine whether the power receptacle <NUM> is coupled to a power insert <NUM> based on the one or more feedback signals. For example, the control circuitry <NUM> may receive feedback signals indicating a relatively continuous and/or constant (e.g., within a certain threshold range and/or deviation) power and/or resonance in the power conversion circuitry <NUM>. In some examples, the control circuitry <NUM> may determine that a relatively continuous and/or constant power and/or resonance indicates that no (and/or negligible) power is being transferred to the power insert <NUM> and/or induction heating tool(s) <NUM>. Thereby, the control circuitry <NUM> may determine the power receptacle <NUM> is not coupled to a power insert <NUM>. As an alternative example, the control circuitry <NUM> may receive feedback signals indicating a relatively discontinuous and/or changing (e.g., outside of the threshold range and/or deviation) power and/or resonance in the power conversion circuitry <NUM>. From this, the control circuitry <NUM> may determine substantial (and/or non-negligible) power is being transferred to the power insert <NUM> and/or induction heating tool(s) <NUM>, and thus determine the power receptacle <NUM> is coupled to a power insert <NUM>.

In some examples, the control circuitry <NUM> may control the power conversion circuitry <NUM> based on whether the power receptacle <NUM> is coupled to a power insert <NUM>. For example, the control circuitry <NUM> may send one or more control signals to the power conversion circuitry <NUM> representative of one or more commands to reduce a level, amplitude, and/or amount of induction-type power generated by the power conversion circuitry <NUM> when the power receptacle <NUM> is not coupled to a power insert <NUM>. As another example, the control circuitry <NUM> may send one or more control signals to the power conversion circuitry <NUM> representative of one or more commands to disable the power conversion circuitry <NUM> when the power receptacle <NUM> is not coupled to a power insert <NUM>. For example, the control circuitry <NUM> may send one or more control signals to the power conversion circuitry <NUM> representative of one or more commands to cease generating induction-type power, cease converting power, and/or cease adding electrical power to the electrical bus. Alternatively, or additionally, the control circuitry <NUM> may send one or more control signals to the power conversion circuitry <NUM> representative of one or more commands to increase and/or decrease an amount (and/or magnitude) of induction-type power generated by the power conversion circuitry <NUM> (and/or enable the power conversion circuitry <NUM>) when the power receptacle <NUM> is coupled to a power insert <NUM>.

In the example of <FIG>, the power conversion circuitry <NUM> includes an input circuit <NUM>, and a conversion circuit <NUM>. As shown, the input circuit <NUM> of the power conversion circuitry <NUM> receives input power from the power source <NUM>. The input circuit <NUM> is configured to perform preliminary (e.g., pre-regulating) operations upon the input power, so as to condition the input power for the conversion circuit <NUM>. In some examples, the input circuit <NUM> is configured to provide the conversion circuit <NUM> with pre-regulated power on an electrical bus through which the input circuit <NUM> and conversion circuit <NUM> are in electrical communication. For example, the input circuit <NUM> may provide direct current (DC) power on the bus. In some examples, the input circuit <NUM> may comprise one or more rectifiers and/or one or more preregulator circuits (e.g., one or more boost converters, stacked boost converters, buck converters, boost-buck converters, and/or other circuits).

In some examples, operation of the input circuit <NUM> is regulated and/or controlled by the control circuitry <NUM> via one or more control signals. For example, the input circuit <NUM> may be configured to adjust a voltage level of the pre-regulated power output by the input circuit <NUM> by changing characteristics (e.g., activate/deactivate, open/close, turn off/on, etc.) of one or more controllable circuit elements (e.g., transistors, relays, switches, etc.) of the input circuit <NUM>. In such an example, the control circuitry <NUM> may adjust the characteristics (e.g., frequency, duty cycle, etc.) of the one or more control signals to control and/or regulate the operation of the input circuit <NUM> via the one or more controllable circuit elements of the input circuit <NUM>.

In the example of <FIG>, the conversion circuit <NUM> is configured to convert the pre-regulated power provided by the input circuit <NUM> to the induction-type power used by induction heating tool(s) <NUM>. In some examples, the conversion circuit <NUM> comprises an inverter circuit configured to generate AC power from DC power provided by the input circuit <NUM>. In some examples, operation of the conversion circuit <NUM> is regulated and/or controlled by the control circuitry <NUM> via one or more control signals. For example, the control circuitry <NUM> may regulate and/or control one or more characteristics (e.g., frequency, amplitude. ) of the induction-type power provided by the conversion circuit <NUM>, such as in response to input via the user interface <NUM>, for example. In some examples, the control circuitry <NUM> may adjust the characteristics (e.g., frequency, duty cycle, etc.) of the one or more control signals to control and/or regulate the operation of the conversion circuit <NUM> via one or more controllable circuit elements of the conversion circuit <NUM>.

In the example of <FIG>, the conversion circuit <NUM> is in electrical communication with the power receptacle <NUM>. The conversion circuit <NUM> provides the induction-type power to the power receptacle <NUM> via the electrical communication channel (e.g., via an electrical bus). In some examples, the power receptacle <NUM> comprises one portion of a modular transformer <NUM> through which induction-type power is transferred from the induction heating power supply <NUM> to the induction heating tool(s) <NUM>.

In the example of <FIG>, the power receptacle <NUM> is part of the induction heating power supply102. In some examples, the power receptacle <NUM> may be separable from, and/or separate from, the induction heating power supply <NUM>. In some examples, the power receptacle <NUM> may be implemented in a junction box (not shown) of the induction heating system <NUM>. In some examples, a power insert <NUM> may be part of the induction heating power supply <NUM>, rather than a power receptacle <NUM>.

As shown, the power receptacle <NUM> is in electrical communication with the power conversion circuitry <NUM>, from which the power receptacle receives induction-type power. In the example of <FIG>, the power receptacle <NUM> comprises a first portion of a modular transformer <NUM>. In particular, the power receptacle <NUM> comprises a primary winding <NUM> of the modular transformer <NUM>, and a primary core <NUM> of the transformer core, as discussed further below. The primary winding <NUM> comprises one or more conductors wound around the primary core <NUM> of the power receptacle <NUM>. The primary winding <NUM> may be hermetically sealed within a housing of the power receptacle <NUM>, such that the conductors of the primary winding <NUM> are not exposed.

In some examples, the primary winding <NUM> may comprise one or more fluid cooled conductors, such as, for example, a hollow conductor (e.g., copper, aluminum, etc.) cooled by fluid routed through the hollow interior of the conductor, or a conductor within hollow tubing cooled by fluid routed over the conductor within the hollow tubing. In some examples, a cooling system (not shown) may connect to the primary winding <NUM> to introduce and/or remove cooling fluid. In some examples, such cooling may assist in mitigating heat produced by electrical current flowing through the primary winding <NUM>.

As shown, the power receptacle <NUM> also includes an opening <NUM> sized and/or configured to receive a power insert <NUM> comprising a second portion of the modular transformer <NUM>, as further discussed below. In the example of <FIG>, a connection detection switch <NUM> protrudes into the opening. As shown, the connection detection switch <NUM> is a movable mechanical switch that is actuated when the power insert <NUM> is coupled to the power receptacle <NUM> via insertion into the opening <NUM>. In some examples, the connection detection switch <NUM> may be an electrical switch, jumper, resistor, circuit, or some other signal generating connection detector. In some examples, actuation of the connection detection switch <NUM> completes or breaks a connection detection circuit (not shown), or a portion of a connection detection circuit. In some examples, the connection detection circuit (or some other circuit) is configured to send a connection signal to the control circuitry <NUM> representative of the connection status of the power receptacle <NUM> and/or power insert <NUM> in view of the connection detection circuit and/or connection detection switch <NUM>. In some examples, actuation of the connection detection switch <NUM> may otherwise indicate to the control circuitry <NUM> the connection status of the power receptacle <NUM> and/or power insert <NUM>.

In the example of <FIG>, there are shown three power inserts 204a, 204b, 204c and two induction heating tools 108a, 108b. While shown as being similar in <FIG>, in some examples, the induction heating tools <NUM> may be entirely different. As shown, both induction heating tools <NUM> include an induction heating coil <NUM> configured in a stacked and/or pancake spiral pattern. In some examples, the induction heating coil <NUM> may be arranged in some other configuration and/or pattern, such as to fit a particular workpiece and/or weld joint configuration, for example. In some examples, the induction heating coil <NUM> may be implemented using a fixture for repeatable heating of a consistent type of joint. In some examples, the induction coil <NUM> may comprise a Litz wire (e.g., a jacketed Litz wire). In some examples, the induction coil heating coil <NUM> may be secured onto and/or into an insulating material (e.g., sewn into an insulating blanket). In some examples, the induction heating tool <NUM> may be moved by a robotic positioning system in tandem along a welding path together with a conventional welding head, for example a TIG head or any other known type, which "follows" the pre-heating head.

In the example of <FIG>, the induction heating tools <NUM> and/or induction heating coils <NUM> are configured to receive induction-type power from the induction heating power supply <NUM> via a power insert <NUM>. In some examples, the induction heating tools <NUM> may further be configured to receive coolant from the induction heating power supply <NUM> and/or some other source. As shown, the induction heating tools <NUM> include adapters <NUM> configured to allow the induction coils <NUM> to electrically connect to the power inserts <NUM>. The adapters <NUM> connect with conventional plugs of the induction tools <NUM> on one end, and are configured for electrical connection to the power inserts <NUM> on the other end. The adapters <NUM> allow for conventional induction heating tools <NUM> to be used with the power inserts <NUM>. In some examples, the adapters <NUM> may be omitted, such as for more recent versions of the induction heating tool(s) <NUM>.

In the example of <FIG>, the induction heating coils <NUM> of the induction heating tool 108a are in electrical communication with power insert 204a, via a fixed connection. Thus, the induction heating tool 108a is only connectable to the power receptacle <NUM> via the power insert 204a. As shown, the induction heating coils <NUM> of induction heating tool 108b are in electrical communication (e.g., via adapters <NUM>) with plugs <NUM> that are configured to connect to both/either power insert 204b and/or power insert 204c. In some examples, the plugs <NUM> may be configured to connect to a wide variety of different power inserts <NUM>. Thus, the induction heating tool 108b is connectable to the power receptacle <NUM> via both/either power insert 204b and/or power insert 204c. When the power receptacle <NUM> is coupled to the power insert <NUM> of an induction heating tool <NUM>, the modular transformer <NUM> is completed and the induction heating tool <NUM> may receive induction-type power from the induction heating power supply <NUM>, so that the induction heating tool <NUM> can perform an induction heating operation.

In the example of <FIG>, the power inserts <NUM> comprise second portions of the modular transformer <NUM>. Each power insert includes a secondary winding <NUM> and a secondary core <NUM> of the modular transformer <NUM>. The secondary winding <NUM> comprises one or more conductors twisted in a helix (and/or other pattern) to encircle the secondary core <NUM> of the power insert <NUM>. The secondary winding <NUM> may be hermetically sealed within a housing of the power insert <NUM>, so there is no exposed wiring.

In some examples, the secondary winding <NUM> may comprise one or more fluid cooled conductors, such as, for example, a hollow conductor (e.g., copper, aluminum, etc.) cooled by fluid routed through the hollow interior of the conductor, or a conductor within hollow tubing cooled by fluid routed over the conductor within the hollow tubing. In some examples, a cooling system (not shown) may connect to the secondary winding <NUM> (e.g., via the adapters <NUM>) to introduce and/or remove cooling fluid. In some examples, such cooling may assist in mitigating heat produced by electrical current flowing through the secondary winding <NUM>. In some examples, the cooling fluid may also be used to cool the induction heating coil <NUM>.

Different power inserts <NUM> may have differently configured secondary windings <NUM> (e.g., with different numbers of winding turns). In the example of <FIG>, the secondary winding 212a of the power insert 204a has the most turns of the power inserts <NUM>, and the secondary winding 212b of the power insert 204b has the least turns of the power inserts <NUM>, with the secondary winding 212c of the power insert 204c falling in between. As shown, the secondary winding 212c of the power insert 204c have the same number of turns as the primary winding <NUM> of the power receptacle <NUM>.

<FIG> shows an example of the modular transformer <NUM> that is completed (and/or formed) when the power receptacle <NUM> is coupled to one of the power inserts <NUM>. When the power insert <NUM> is securely inserted into (and/or coupled to) the power receptacle <NUM>, the primary core <NUM> of the power receptacle <NUM> and secondary core <NUM> of the power insert <NUM> align to complete the modular transformer <NUM>. As shown, the connection detection switch <NUM> is displaced by the coupling, thereby completing the connection detection circuit so as to provide a detectable indication (e.g., a signal or cessation of a signal) to the control circuitry <NUM> that the modular transformer <NUM> is completed.

<FIG> is another illustration of the completed modular transformer <NUM>. While the cores <NUM>, <NUM> and windings <NUM>, <NUM> are illustrated as being adjacent one another for ease of illustration in <FIG> and <FIG>, <FIG> shows a more practical implementation of the completed modular transformer <NUM>. As shown, the ferromagnetic core of the modular transformer <NUM> is divided into two primary cores <NUM> (e.g., upper core 207a and lower core 207b) of the power receptacle <NUM> and one secondary core <NUM> of the power insert <NUM>. The primary cores <NUM> are aligned on opposite sides of the opening <NUM> of the power receptacle <NUM>. Primary windings <NUM> encircle the primary cores <NUM>. The secondary core <NUM> is retained by the power insert <NUM>, with secondary windings <NUM> encircling the secondary core <NUM>. The power receptacle <NUM> and power insert <NUM> are configured such that the secondary core <NUM> is aligned with the primary cores <NUM> when the power insert <NUM> is fully inserted into (and/or coupled to) the power receptacle <NUM>. In some examples, the primary winding <NUM> and secondary winding <NUM> may be concentrically aligned (e.g., with the cores <NUM>, <NUM> at their respective centers) when the power insert <NUM> is fully inserted into (and/or coupled to) the power receptacle <NUM>.

<FIG> shows an example cross-section of the completed modular transformer <NUM>. While the modular transformer <NUM> in <FIG> shows the primary windings <NUM> and secondary windings <NUM> as having the same winding direction, in some examples, the primary windings <NUM> and secondary windings <NUM> may have opposite winding directions. As shown, there are approximately twice as many secondary windings <NUM> as primary windings <NUM>, making the modular transformer <NUM> a <NUM>:<NUM> step up transformer. In some examples, the modular transformer <NUM> may be configured differently depending on the primary windings <NUM> and/or secondary windings <NUM> of the power receptacle <NUM> and/or power insert <NUM> used to complete the modular transformer <NUM>.

In operation, an operator may use different power receptacles <NUM> and/or power inserts <NUM> (each having potentially different primary winding <NUM> and/or secondary winding <NUM> configurations) with different induction heating power supplies <NUM> and/or induction heating tools <NUM> in order to achieve the desired results. By using different power receptacles <NUM> and/or power inserts <NUM>, the operator may manipulate the ratio of primary windings <NUM> to secondary windings <NUM> without having to directly access and/or manipulate the exposed wire windings of the transformer. If the ratio of primary windings <NUM> to secondary windings <NUM> is less than ideal for impedance matching and/or the desired step up/down voltage, an operator can use a different power receptacle <NUM> and/or power insert <NUM>, with a different number (and/or configuration) of primary windings <NUM> and/or secondary windings <NUM>, without having to directly manipulate any exposed wire windings.

While the modular transformer <NUM> of <FIG> and <FIG> is depicted with two separated primary cores 207a, 207b and one secondary core 213a, in some examples, there may be only one primary core <NUM>. For example, there may be only an upper primary core 207a or only a lower primary core 207b, with corresponding windings <NUM>. In such an example, the primary core <NUM> may comprise one complete half of the core of the modular transformer <NUM>, while the secondary core 213a may comprise the other half. Additionally, though the modular transformer <NUM> of <FIG> is shown with an E-core, in some examples, the modular transformer <NUM> may instead be configured with one or more other core types, such as a U-core, a P-core, a pot core, a toroid core, etc..

<FIG> shows an example coupling control process <NUM> of the present disclosure. In some examples, the coupling control process <NUM> may be implemented via machine readable instructions, such as may be stored in memory circuitry <NUM> and/or executed by the one or more processors <NUM>. In some examples, the coupling control process <NUM> may be implemented via discrete and/or analog circuitry of the control circuitry <NUM>. The coupling control process <NUM> is configured to control the power conversion circuitry <NUM> based on whether the power receptacle <NUM> is coupled to the power insert <NUM>. In some examples, the coupling control process <NUM> may be executed by one or more other control process and/or in conjunction with one or more other control processes.

In the example of <FIG>, the coupling control process <NUM> is implemented as a continuously iterating and/or looping operation in block <NUM>. At block <NUM>, the coupling control process <NUM> determines whether the power receptacle <NUM> is coupled to the power insert <NUM>. The coupling control process <NUM> may make this determination based, at least in part, on feedback received from the power conversion circuitry <NUM>, and/or the connection detection switch <NUM> (and/or associated connection detection circuit), as discussed above. If the coupling control process <NUM> determines that the power receptacle <NUM> is coupled to the power insert <NUM>, the coupling control process <NUM> proceeds to block <NUM>. If the coupling control process determines that the power receptacle <NUM> is not coupled to the power insert <NUM>, the coupling control process <NUM> proceeds to block <NUM>. After blocks <NUM> and/or <NUM>, the coupling control process returns to block <NUM>.

If the coupling control process <NUM> determines that the power receptacle <NUM> is coupled to the power insert <NUM>, block <NUM> of the coupling control process <NUM> executes. At block <NUM>, the coupling control process <NUM> enables normal power generation of the power conversion circuitry <NUM> to proceed. If normal power generation had previously been interrupted (e.g. by block <NUM>), the coupling control process <NUM> resumes normal power generation.

If the coupling control process determines that the power receptacle <NUM> is not coupled to the power insert <NUM>, block <NUM> executes. At block <NUM>, the coupling control process <NUM> interrupts normal power generation of the power conversion circuitry <NUM>, so that induction-type power is not continually added to the system bus with nowhere to go. In some examples, the interruption of normal power generation may comprise disabling of the power conversion circuitry <NUM> (e.g., via a cessation of control signals or use of control signals configured to disable), reducing the amount of induction-type power produced by the power conversion circuitry <NUM> (e.g., via representative control signals), and/or other appropriate action. In some examples, the interruption of normal power generation may further comprise generating a warning (and/or alert/alarm), such as via the user interface <NUM> and/or some other interface (e.g., the interface of a remote device, mobile device, etc.). Afterwards, the coupling control process <NUM> returns to block <NUM>.

Claim 1:
An induction heating system (<NUM>), comprising:
a primary power coupler (<NUM>) comprising a first primary magnetic core (207a), a second primary magnetic core (207b), and an opening (<NUM>) positioned between and separating the first primary magnetic core (207a) and the second primary magnetic core (207b), the first primary power coupler (<NUM>) configured for electrical communication with an induction heating power supply (<NUM>); and
a secondary power coupler (204a) comprising a second magnetic core (213a), the second power coupler (204a) configured for electrical communication with an induction heating tool (<NUM>),
wherein the primary power coupler (<NUM>) and secondary power coupler (204a) are configured to align the first primary magnetic core (207a) and the second primary magnetic core (207b) with the secondary magnetic core (213a) when the secondary power coupler (204a) is inserted into the opening (<NUM>), the alignment of the first primary magnetic core (207a), the second primary magnetic core (207b), and the secondary magnetic core (213a) forming a transformer (<NUM>) through which the induction heating power is transferrable to the induction heating tool (<NUM>).