In order to solve the confusion of single-frequency induction heating in dealing with complex surface hardening processes such as gears, through continuous exploration and experimentation, synchronous dual-frequency induction heating technology has emerged, which is a true gear surface induction hardening technology. In recent years, foreign synchronous dual-frequency induction heating technology has developed rapidly and has been widely used in the heat treatment of complex surface workpieces such as gears in the automotive and aerospace industries.
Simultaneous Dual Frequency (SDF®) is a heat treatment of a workpiece using two different frequencies (high frequency and intermediate frequency) on one induction coil. The SDF® power supply consists of an HF (high frequency) and an MF (intermediate frequency) power supply for normal power output, using IGBT technology to superimpose high frequency oscillations on the basis of intermediate frequency oscillations. Moreover, the power of HF (high frequency) and MF (intermediate frequency) can be continuously adjusted from 2% to 100%, with integrated PLC control, with multiple program time and power settings, especially suitable for handling complex surfaces like gears. Job task. The output ratio of the two frequencies and the hardening depth at the root and the tooth surface can be adjusted according to the processing requirements of the workpiece.
At present, Germany's Eldec Induction Heating Equipment Co., Ltd.'s SDF® synchronous dual-frequency induction heating equipment can reach more than 3MW, which can fully meet the heat treatment requirements of various workpieces. Through the optimal matching of different heat treatment parameters, a good profile hardening effect can be obtained (as shown in Fig. 3 and Fig. 4).
Second, the application of SDF® synchronous dual-frequency induction heating technology
The development of SDF technology has made it possible to apply rapid, high energy density energy to induction heat treatment of complex surface workpieces with similar gears. The goal is to synchronize the medium-high frequency energy to the surface of the workpiece that needs to be heat treated, which will save energy and reduce the amount of deformation to meet the requirements of the next step. In fact, the process of grinding similar parts after heat treatment of some workpieces will no longer be required.
The aviation industry is the most demanding to control costs and maintain the highest standards of safety and quality. Boeing Company of the United States is based on the requirements for product quality and environmental protection. Some of its gears, such as straight umbrella (cone) gears, use SDF induction hardening technology instead of the original carburizing and quenching process. It has been proven that SDF induction hardening technology is a completely viable option to achieve the minimum amount of deformation.
Similar to such straight umbrella (cone) gears (see Fig. 5), it is very difficult to grind teeth after quenching to correct the amount of deformation because the shape of the crest is complicated for grinding teeth. This necessitates control of the amount of quenching deformation to achieve the final tolerance requirements. The SDF induction hardening treatment time of the gear is only about 40% compared with the conventional carburizing and quenching, thus simplifying the machining process of the gear, reducing the deformation amount and shortening the surface treatment time.
Many similar workpieces with complex contours have previously been treated with a carburizing and quenching process because of the long heat treatment and thermal deformation. In contrast, SDF induction technology can control the amount of quenching deformation to the minimum we expect.
Heat treatment of automotive CV joints and drive shafts is a complex and time consuming process involving materials, machinability, and differences between batches. The SDF induction hardening process supplies the required energy to the workpiece in the shortest possible time. Thanks to the simultaneous action of the two frequencies, a controlled and reproducible hardened layer depth is achieved, and the controlled energy output provides minimal deformation and excellent repeatability, which makes us always " Green production is possible. Eldec's SDF induction hardening technology uses high energy density energy to eliminate the cost of production and the highest energy consumption in the production process, thereby saving costs (see Figure 6) and reducing energy consumption by a factor of three.
Another example is the steering device of a car that requires surface induction heat treatment to achieve its complex surface hardening. Figure 7 is two examples of a large number of tests to confirm the quality of surface induction hardening.
In addition, there are other application examples: spiral umbrella (cone) gear (see Figure 8), driven planetary gear (see Figure 9), and other pictures of the workpiece (see Figure 10).
Third, SDF® induction heating equipment
The implementation of SDF® technology – the eldec MIND device (see Figure 11).
The modular design of the MIND device provides the user with maximum flexibility and selectivity. Based on this modular design, eldec offers different solutions for different customers to suit the needs of different customers, so that customers can purchase the most suitable equipment at the best price.
The MIND modular equipment will be tailored to the customer's requirements and can also be supplied with a manually controlled solution, as the heat treatment system has different control methods and requirements; or it can be placed in the entire production line as a heat treatment unit, thus becoming a The complete production chain, including pre-heat treatment, heat treatment and heat treatment, is flexible and can be configured differently depending on the heat treatment task and the workpiece. The equipment configuration depends on the size of the workpiece, the desired heat treatment result, the size of the treatment batch, and the like.
A special feature of the MIND series is the ability to integrate with the entire production line to accommodate today's integrated management of savings, time, energy and cost.
Germany Eldec Induction Heating Equipment Co., Ltd. has a patented mature SDF® synchronous dual-frequency induction heating technology. It has many customers in Europe and the United States, and is well-known in the German BMW (BMW) automobile manufacturer and German (Volkswagen) automobile manufacturing. Merchants, the United States Boel ing aircraft manufacturing company. The German IGBT type SDF® currently available from Eldec Induction Heating Equipment has a power range of 15 to 3000 kW. At the same time, it can be designed and manufactured according to the customer's heat treatment requirements.
Fourth, the conclusion
Saving energy and protecting resources are our eternal goals. Reducing fuel emissions - whenever and wherever - is our goal. “Green†is not only a responsibility for the manufacturing industry, but also requires all of us to make efforts. Reducing energy consumption is a win-win solution for manufacturers to develop and enhance their competitive advantage.
For the manufacturer, not only is the production cost reduced, but more importantly, the use of eldec SDF® induction heat treatment technology can be used to visually see the reduction in environmental impact. Moreover, SDF induction quenching only applies as little energy as possible to the part where the workpiece needs to be processed, so that the workpiece has only minimal deformation.
Our goal is to develop new technologies to better conserve energy in the production process, protect our ecological environment, and finally achieve “green productionâ€.
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