Development history of foreign induction heat treatment technology
2018-11-08 12:13:11
Modern automobile production is a high-efficiency, environmentally-friendly, large-scale production of water. Induction heat treatment technology has many advantages such as high quality, high efficiency, energy saving, environmental protection, etc., meets the needs of modern automobile production, has been widely applied, and the technical level has been rapidly improved.
International advanced induction hardening technology
1, the power supply
Foreign IGBT, MOSFET and SIT all-solid-state transistor power supply technology is gradually matured, and has been commercialized and serialized. Currently, there are 1200kW, 50kHz; 50~100kHz, 30~600kW; 300kW, 80kHz; low frequency band has the trend of replacing thyristor power supply; Using a parallel oscillating circuit, the SIT uses a series resonant circuit with a power of up to 1000 kW, a frequency of 200 kHz, and 400 kW, 400 kHz. They are ideal replacements for tube-type high-frequency power supplies. When the output power is the same as that of the tube power supply, the power saving is 35% to 40%, the installation area is saved by 50%, and the cooling water is saved by 40% to 50%. With the advancement of technology, MOSFETs are expected to replace SIT in the field of high frequency induction hardening.
2, quenching machine
Induction hardening machines are becoming more automated, CNC control is increasing, and machine tools for automatic sorting of parts and automatic identification of incoming parts are increasing.
(1) Universal quenching machine
The universal quenching machine is developed in the direction of flexibility. A quenching machine can inductively quench the different parts with different performance requirements. A crankshaft quenching machine developed by Germany, the flanged induction hardening flexible machining system is slightly adjusted to handle similar workpieces of different sizes; for shaft parts within a certain diameter range (such as 30mm) and lengths of 300 to 800 mm, For shaft parts with similar quenching requirements, the quenching machine can automatically program 14 programs to automatically identify the incoming parts; Robotron.Eiotherm recently introduced a twin-spindle vertical quenching machine for quenching and tempering the workpiece in a compact process unit. It can handle wheel axles, three-slot sleeves and Other universal joint parts. It only takes 2~5min to convert workpieces. It can be programmed by computer. According to the workpiece number, the relevant process data can be adjusted within 2 minutes. The GH company numerical control quenching equipment introduced by FAW High versatility, automation, multi-stage variable power shifting on complex parts, easy programming and easy operation. Figure 1 shows the CNC hardening machine from GH.
(2) Special hardening machine
The special quenching machine is more specialized, using mechanical parts and lower parts, heating, quenching, tempering, straightening, and inspection are completely automatic. Advanced computer control technology can monitor and display the quenching process and process parameters, track all operating procedures, and if the fault is found or the process parameters deviate from the given value, the unqualified parts will be automatically corrected or automatically listed, and the control system will be suspended and alarmed. At the same time, the nature of the fault and the action to be corrected are displayed on the screen. More advanced control systems also accommodate fluctuations in the chemical composition of the material and automatically adjust the specific power or heating time to ensure the quality of the induction hardened parts. For example, the horizontal half-axis quenching machine of the Kawasaki Plant of Japan High Frequency Co., Ltd., the upper tail plant can simultaneously quench three half shafts, and the Gunma plant can simultaneously quench two half shafts. The machine tool is actually an induction heat treatment production line. The fluorescent flaw detection inspection requires one worker, and the rest are automatically carried out.
(3) Application of robot
A vertical universal quenching machine manufactured by Japan High Frequency Co., Ltd. is equipped with a robot. The robot scans a two-inch sensor in sequence to make a plastic plate discolor. Although the power supply is only 3 kW, it is also The application trend of robots in induction heat treatment can be seen.
(4) Mechatronics
The power supply, the quenching machine and the cooling system are combined into a complete set, which has the advantages of small footprint, high production efficiency, and easy installation and commissioning. The crankshaft fixed heating and quenching device recently introduced abroad is only 1/4 of the combined complete plant.
3, quenching process
(1) Static crankshaft induction hardening
The first two units using the new technology of static crankshaft induction hardening have been used in Ford's V6 and V8 crankshaft quenching and tempering processes, showing a good market prospect. Its characteristics are: short heating time, generally only 1.5 ~ 4s, traditional process is 7 ~ 12s; high electrical efficiency, low cost; allow a large gap between the inductor and the workpiece, easy to adjust; easy to operate, good repeatability Easy to maintain; small footprint, only about 20% of the original.
(2) Low hardenability steel gear quenching
At present, many automobile factories in Russia use low-hardenability steel for integral induction heating surface quenching. They have been widely used in automobiles, tractor rear axle gears, excavator gears, transmission cross shafts, rolling bearings for train cars, automobile leaf springs, railway coil springs. Etc., achieved greater economic benefits.
(3) Dual frequency induction heating quenching
Foreign dual-frequency quenching is mainly used for gears. In the 1990s, the United States used a 10 kHz intermediate frequency and a 150 kHz high-frequency power supply to first heat the gear in the intermediate frequency inductor, then quickly drop it into the high-frequency inductor to heat it, and finally fall into the oil to quench. In the 21st century, this process has made new progress. For example, GH Company adopts the power electronic switch frequency to make the heating of the gear tip and the heel of the gear more uniform, which better guarantees the quenching quality of the gear.
International advanced induction hardening technology
1, the power supply
Foreign IGBT, MOSFET and SIT all-solid-state transistor power supply technology is gradually matured, and has been commercialized and serialized. Currently, there are 1200kW, 50kHz; 50~100kHz, 30~600kW; 300kW, 80kHz; low frequency band has the trend of replacing thyristor power supply; Using a parallel oscillating circuit, the SIT uses a series resonant circuit with a power of up to 1000 kW, a frequency of 200 kHz, and 400 kW, 400 kHz. They are ideal replacements for tube-type high-frequency power supplies. When the output power is the same as that of the tube power supply, the power saving is 35% to 40%, the installation area is saved by 50%, and the cooling water is saved by 40% to 50%. With the advancement of technology, MOSFETs are expected to replace SIT in the field of high frequency induction hardening.
2, quenching machine
Induction hardening machines are becoming more automated, CNC control is increasing, and machine tools for automatic sorting of parts and automatic identification of incoming parts are increasing.
(1) Universal quenching machine
The universal quenching machine is developed in the direction of flexibility. A quenching machine can inductively quench the different parts with different performance requirements. A crankshaft quenching machine developed by Germany, the flanged induction hardening flexible machining system is slightly adjusted to handle similar workpieces of different sizes; for shaft parts within a certain diameter range (such as 30mm) and lengths of 300 to 800 mm, For shaft parts with similar quenching requirements, the quenching machine can automatically program 14 programs to automatically identify the incoming parts; Robotron.Eiotherm recently introduced a twin-spindle vertical quenching machine for quenching and tempering the workpiece in a compact process unit. It can handle wheel axles, three-slot sleeves and Other universal joint parts. It only takes 2~5min to convert workpieces. It can be programmed by computer. According to the workpiece number, the relevant process data can be adjusted within 2 minutes. The GH company numerical control quenching equipment introduced by FAW High versatility, automation, multi-stage variable power shifting on complex parts, easy programming and easy operation. Figure 1 shows the CNC hardening machine from GH.
(2) Special hardening machine
The special quenching machine is more specialized, using mechanical parts and lower parts, heating, quenching, tempering, straightening, and inspection are completely automatic. Advanced computer control technology can monitor and display the quenching process and process parameters, track all operating procedures, and if the fault is found or the process parameters deviate from the given value, the unqualified parts will be automatically corrected or automatically listed, and the control system will be suspended and alarmed. At the same time, the nature of the fault and the action to be corrected are displayed on the screen. More advanced control systems also accommodate fluctuations in the chemical composition of the material and automatically adjust the specific power or heating time to ensure the quality of the induction hardened parts. For example, the horizontal half-axis quenching machine of the Kawasaki Plant of Japan High Frequency Co., Ltd., the upper tail plant can simultaneously quench three half shafts, and the Gunma plant can simultaneously quench two half shafts. The machine tool is actually an induction heat treatment production line. The fluorescent flaw detection inspection requires one worker, and the rest are automatically carried out.
(3) Application of robot
A vertical universal quenching machine manufactured by Japan High Frequency Co., Ltd. is equipped with a robot. The robot scans a two-inch sensor in sequence to make a plastic plate discolor. Although the power supply is only 3 kW, it is also The application trend of robots in induction heat treatment can be seen.
(4) Mechatronics
The power supply, the quenching machine and the cooling system are combined into a complete set, which has the advantages of small footprint, high production efficiency, and easy installation and commissioning. The crankshaft fixed heating and quenching device recently introduced abroad is only 1/4 of the combined complete plant.
3, quenching process
(1) Static crankshaft induction hardening
The first two units using the new technology of static crankshaft induction hardening have been used in Ford's V6 and V8 crankshaft quenching and tempering processes, showing a good market prospect. Its characteristics are: short heating time, generally only 1.5 ~ 4s, traditional process is 7 ~ 12s; high electrical efficiency, low cost; allow a large gap between the inductor and the workpiece, easy to adjust; easy to operate, good repeatability Easy to maintain; small footprint, only about 20% of the original.
(2) Low hardenability steel gear quenching
At present, many automobile factories in Russia use low-hardenability steel for integral induction heating surface quenching. They have been widely used in automobiles, tractor rear axle gears, excavator gears, transmission cross shafts, rolling bearings for train cars, automobile leaf springs, railway coil springs. Etc., achieved greater economic benefits.
(3) Dual frequency induction heating quenching
Foreign dual-frequency quenching is mainly used for gears. In the 1990s, the United States used a 10 kHz intermediate frequency and a 150 kHz high-frequency power supply to first heat the gear in the intermediate frequency inductor, then quickly drop it into the high-frequency inductor to heat it, and finally fall into the oil to quench. In the 21st century, this process has made new progress. For example, GH Company adopts the power electronic switch frequency to make the heating of the gear tip and the heel of the gear more uniform, which better guarantees the quenching quality of the gear.
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