EFD induction heating power supply <br> Now the development trend of induction power supply is that its main control adopts all-digital control mode, and the core part adopts IGBT inverter module from low frequency to high frequency. The module has better durability and is in complex and harsh environment. The working condition will not be damaged, and the power output circuit can adopt series compensation or parallel compensation as needed.
In order to improve efficiency and energy saving, especially in the factory, we use diode full-regulation circuit in primary rectification. The advantage is that the power factor of the power supply is constant, and both are above 95%, which is very beneficial for energy saving.
The matching box is calculated according to the specific application to select the appropriate transformer and capacitor. Only in this case can the required processing frequency be realized, and the full power output can be realized as much as possible at this frequency.
The grounding protection of the ordinary quenching machine is only to look at the gap between the inductor and the workpiece when debugging before heating. Most of the functions are turned off during the actual operation, and the EFD induction heating power supply is in the heating process, the workpiece and The sensors are grounded to each other in real time.
For the induction heating power supply, we will monitor the output power, frequency, voltage and current in real time. The running curve will be displayed on the computer screen first. Once the upper and lower limits are exceeded, the control system will give an alarm. At the same time, it is easy to find reasons.
The inductive power supply works closely with the specific application. If a general-purpose power supply is used in a special case, the frequency will not be the desired frequency, and the output efficiency will be very low. The actual output of the 300 kW power supply may reach 100 kW. The maximum will not exceed 150kW.
EFD induction hardening machine
Crankshaft quenching EFD's crankshaft quenching machine can achieve rounded quenching and non-rounded quenching, which can be achieved for the crankshaft's connecting rod neck, crankshaft neck, flange and oil seal end quenching. For the crankshaft, it can also realize the residual heat tempering and induction tempering. The crankshaft induction coil has a long service life. The most basic one is to reach 50,000 times of heating. Only a few simple maintenance is needed in the middle. Our current technology is approaching 100,000 times of heating. The deformation control of the crankshaft heat treatment is very important. Generally, the crankshaft induction heat treatment deformation of the bridge is carried out, and the EFD is normally controlled below 0.2 mm. The requirements for power supply for German, Japanese and North American crankshaft induction heat treatments are different, so different powers and frequencies are required for different customers. EFD's fully automatic crankshaft quenching machine can use robot loading and unloading, and can also use trolley type loading and unloading. If the production cycle is relatively high, the stepping machine can also be used for loading and unloading. In addition, EFD's heavy-duty crankshaft quenching machine can process crankshafts up to 10m in length.
1. Camshaft quenching <br> For the quenching of camshafts, most of them may still use scanning quenching. Scanning from top to bottom with a circular coil, foreign countries now mainly use profile quenching. In order to improve efficiency, it can be used in a station. Simultaneous quenching of the two camshafts. With profile quenching, the hardened layer distribution is very uniform. The thickness of the hardened layer of the peach tip is relatively large when the circular scanning is quenched. The other parts are shallow, and the crack or material peeling phenomenon occurs when the cam is actually used. The profile quenching is performed. This problem can be avoided. If the space between the camshafts is relatively small, when one of the camshafts is quenched, the other camshaft may be tempered. At this time, the EFD uses three camshafts to simultaneously shape and quench. EFD automatic camshaft quenching machine adopts robot loading and unloading. If cost saving is considered, double-station camshaft quenching machine can also be used (one power supply and two output turns alternately, when one cam is heated to switch to another A cam heating), if you want to improve efficiency, EFD can also provide four-station camshaft quenching machine.
2. Profiled quenching of pinion <br> This kind of quenching method EFD has also applied for a patent. This technology requires dual-frequency or multi-frequency power supply, short-time, high-power heating, and the low frequency band plays the role of preheating. The high frequency band has the effect of quenching. The computer simulation of EFD has been used very early. If the power and frequency of the profile quenching are not suitable, the quenched parts are waste products. Through the computer simulation test and simulation calculation, the required power, frequency and quenching parameters are confirmed in advance. As well as the coil structure, the actual quenching results are very close to the computer simulation.
3. Large ring gear and raceway quenching
For ring gears with a modulus greater than 6, this requires single-tooth quenching, mainly for single-tooth quenching of the groove and profile. EFD's quenching machine is equipped with a probe that automatically pairs each tooth before heating. The position is accurately detected, and then the position information is transmitted to the control system, and the control system positions the sensor to achieve accurate gear quenching. No soft belt quenching is also the patented technology of EFD. At present, many non-soft belt quenching machine tools have been successfully sold. Customers have large bearing manufacturers such as SKF and Schaeffler, and EFD sells slewing bearings without soft belt quenching machine tools. The diameter has reached 8m, and the machine tool ≥10m is currently being studied. For the large ring gear with low output, the customer wants to save space. EFD has a cantilever type quenching machine, which is convenient to operate. The sensor on the arm is extended to retract, and the loading and unloading is convenient, saving the floor space. The machine tool can process workpieces up to 4m in diameter. If the quenching is specifically for the raceway, EFD also has a tilting quenching machine, which has a relatively high production efficiency. The diameter of the processed EFD has been 6m, and the diameter can be larger. EFD double-head gantry type quenching machine can be used for quenching of teeth or for quenching of channels. The depth of hardened layer of channel is generally 6mm, and even up to 8mm, one head heating can not reach The required depth, in order to increase productivity and reduce the occurrence of cracks, uses a double head, one head provides preheating, and one head performs quenching.
4. Quenching and tempering of ball screw The quenching machine of EFD ball screw is also fully automatic. The screw can be slotted and quenched. The round bar can also be quenched. After hardening, hard milling is used. Simultaneous quenching and tempering on the EFD horizontal machine tool, automatic loading and unloading.
5. Guide rail quenching and tempering <br> The industry is now demanding more and more quenching of guide rails. In order to reduce the deformation and achieve a uniform quenching depth, the development trend of quenching of guide rails is to use three stations to pre-material. Heat, quenching and tempering, the entire loading and unloading of EFD quenching machine is also fully automatic. At present, there is already a rail enterprise in China.
6. Quenching and tempering of car steering gear rack EFD has more advanced steering gear rack automatic quenching and tempering technology. There are two techniques for rack quenching, one is induction hardening technology and the other is conductive. Quenching technology. Induction hardening technology, the cost is relatively high, but the quality and performance of the rack after induction heat treatment is relatively good, so the general rack is using induction hardening technology. EFD's rack automatic quenching machine uses robot or gantry robots for loading and unloading. The EFD automatic conductive quenching machine mainly performs the surface quenching of the rack of the rack, conducts the quenching of the teeth, and then uses the induction tempering of the entire rack. At present, some enterprises at home and abroad, in order to save equipment costs, improve the mechanical properties of the rack, many of the tooth back and teeth are used for conductive quenching, EFD also has corresponding rack processing customers in China. In order to improve the processing efficiency, EFD can perform simultaneous induction hardening at three racks in the same station, and then temper at another station. For the induction quenching and tempering of the rack, the choice of power and frequency, and the shape of the inductor are quite important parameters. The rack is easily deformed during the heat treatment process. How to control the deformation is also a key technology.
7. Quenching and tempering of constant velocity joints <br> The current development trend is automatic quenching, and some auxiliary functions, such as automatic loading and unloading table, can be added before the quenching of the inner cavity and the rod. After cleaning, the marking can be realized, and the eddy current testing equipment can be used to detect the crack and the depth of the hardened layer. Then the workpiece is rustproofed and placed on the blanking table. The whole process is fully automated, and the entire heat treatment unit of EFD is completed. The cycle of the machining process can be 20 ~ 25s / piece. We can also integrate the induction tempering process into induction hardening, and the processing cycle is generally 25 to 30 s.
8. Quenching and tempering of second-generation/three-generation wheel bearings <br> Wheel hub bearings have inner and outer rings. The fully automatic heat treatment unit of EFD wheel bearings consists of two parts, one for inner ring and the other for outer ring. The heat treatment of the inner and outer rings of the hub bearing is performed at the same time on a machine tool. The machining efficiency is very high, including quenching and tempering, and the production cycle is 12s/piece.
9. Synchronizer toothed sleeve induction heating quenching and tempering <br> Originally, the carburizing heat treatment was carried out in the furnace, and now many users need to pressurize the toothed sleeve. After induction heating of the carbon layer on the surface, spraying to the next station, the deformation requirement of the workpiece is very high in this process, and the deformation is limited during the spraying process, and the requirements for the mold are very high. EFD uses three workpieces for simultaneous heating, quenching and tempering. In the tempering, the infrared sensor is used to monitor the temperature. During the whole heat treatment process, the conveyor belt is used for automatic loading and unloading of the workpiece.
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