Luoyang Judian Metal Hot Processing Equipment Co., LTD is mainly engaged in the manufacture of complete sets of equipment in the metal thermal processing industry and the integration of the entire production line.
In addition to the need for additional high temperature treatment, the mechanical aspects of the induction heating process are often arranged in the specified production line. Some local heating processes, especially surface hardening, also require precise control and timing to ensure uniform hardened layer depth and metallurgical quality.
There are various types of equipment, ranging from simple manual loading fixtures suitable for local brazing and soft soldering to fully automatic or CNC machines suitable for quenching shafts such as crankshafts and camshafts and through-heating of steel billets and bars. Most manual loading fixtures are suitable for small batches of variable loads. The main requirements are simplicity, low cost and quick disassembly.
Induction Heating
Common applications are welding heating and simple hardening requirements under high frequency power supply conditions. The fixture is fixed to a workbench, which is bolted to the front of the high frequency generator. If the operation is more complicated, a simpler timer and quenching system is required.
The universal fixture shown has two timers, one for heating and the other for quenching. Since the position of the workpiece relative to the coil can be a critical factor, the system uses an integral coil-fixture locator even when operated manually. The locator is quickly replaced with two nuts, so that one fixture can be assembled while another fixture is in use on the machine. The fixture also includes a coil water cooling line that is connected to the quench water supply. A matching high-frequency transformer is installed in the housing just behind the terminal block.
The degree of automation of the operating machinery depends on the size of the production volume, the number of different types of water-processed parts, the relative labor costs and the payback period of the capital equipment investment. However, in order to achieve acceptable metallurgical quality in induction hardening, all factors must be accurately controlled and reproducible.
Therefore, the parts must be heated and quenched in the same way every time. If the operator only loads and unloads a quenched part in one form, the method is called "semi-automatic". On the other hand, if the parts are not loaded and unloaded by an operator, the method is called "fully automated." Semi-automatic systems are used in the following production scales
The production volume is quite low, and the cost of full automation is too high.
Several parts are processed on one device, and the main fixtures must be replaced and adjusted each time.
The parts are too large.
The shape of the parts is not suitable for automation.
The heat treatment cost accounts for a high proportion of the total cost of the parts.
The production cost is high and the labor cost is low. Fully automated systems are suitable for another production scale, that is,
The production volume is large.
The device system is limited to one part, or different parts can be quickly changed with simple replacement sensors and adjustment fixtures.
The parts are suitable for automation.
The device system can be installed on a production line with equipment for other processes.
Quality control is extremely important. Each of the above items is important and has an impact on the decision to fully automate, regardless of the specific design of the part and the heat treatment technology conditions.
