Crankshaft Hardening system

Crankshaft Technology Process

The machining process of crankshaft is: forging→ normalizing→ mechanical processing→ stress relief annealing→ tempering treatment→ surface heat treatment. Surface heat treatment include high-frequency hardening and low-temperature tempering process. Through these two heat treatment processes, the hardness and wear resistance of the crankshaft surface can be increased. The hardening and tempering hardness can be accurately controlled at 50-55HRC.

Crankshaft Hardening Capacity

The crankshaft hardening system can process different position of various crankshafts, such as fillet hardening, bearing hardening and round corner hardening, the length range is between 500-1500mm.

Crankshaft Hardening System

The crankshaft hardening system mainly includes: crankshaft hardening machine tool, IGBT medium frequency induction heating power supply, hardening liquid circulating cooling system, pure water cooling circulating system, PLC electrical control system, chiller, etc.

The crankshaft hardening system adopts an integral welded lathe bed, which has good rigidity, thermal stability and vibration resistance. The lathe tool adopts a pneumatic self-centering power chuck, which can automatically clamp the work piece, and the tailstock can automatically move on the guide rail to adapt to different size of crankshafts;

The crankshaft hardening system adopts IGBT induction heating power supply, which has high power efficiency, low failure rate and high startup success rate. It has a full set of protection functions and alarm functions; when hardening the connecting rod shaft, the power supply can adjust power automatically, to ensure that the hardened layer of the journal is even;

The lifting system of the induction coil is driven by a brake cylinder and equipped with a buffer device; each hardening transformer is independently suspended, and the spacing between adjacent transformers is adjusted by manual screw to adapt to different sizes of crankshafts, to ensure that the induction coil can track well and the pressure on the crankshaft is minimized, and the hardening deformation of the crankshaft is reduced;

The cooling system adopts soft water circulation cooling process, which can provide low-pressure cooling for the induction heating power supply, and high-pressure cooling for the hardening system and induction coil. Each cooling circuit is equipped with temperature, pressure and flow monitoring and protection devices.

PLC Control System

The crankshaft hardening control system can choose Siemens PLC touch screen and other control systems available, allowing operators to use touch screen to set various process parameters (including voltage, current, heating time, cooling time, heating power, frequency, spray flow, etc. ) , with high control accuracy and automaticity.

Applications:

ROCHO technical team specializes in design and build of induction heating power supply, high-frequency hardening equipment and fully automatic hardening and scanning system. It is widely used in heat treatment industry and can be used for hardening of various work pieces, such as:
1. Gear induction hardening
2. Crankshaft induction hardening
3. Cylinder liner induction hardening
4. Shafts & rods induction hardening
5. Guide rails induction hardening
6. Ball pin induction hardening
7. Bolts and fastener induction hardening
8. Concrete pump tube inner wall induction hardening

Technical Specification:

Model	Power Output	Parts Length	Max Rotate Diameter	Parts Weight	Scanning Length	Dimensions (LWH)
QZCH50	50kW	500mm	15-200mm	50kg	500mm	130014001600mm
QZCH100	100kW	1000mm	30-400mm	150kg	1000mm	170015002300mm
QZCH120	120kW	1200mm	35-400mm	150kg	1200mm	170015002300m
QZCH150	150kW	1500mm	50-400 mm	300kg	1500mm	170015002550mm
QZCH200	200kW	2000 mm	50-500 mm	500kg	2000mm	180018004800mm
QZCH250	250kW	2500 mm	60-500 mm	500kg	2500mm	180018005800mm
Power Supply	380-480V, Three phase, 50Hz/60Hz
Work Piece Type	Induction hardening of various crankshafts, sprockets, various mechanical shafts, spline shafts, pin shafts, etc.
Duty Cycle	100%
Cooling Way	Water cooling
Water Temperature	The device alarms when the water temperature exceeds 40 °C.
Cooling Way	Closed circuit cooling system, air chiller, water chiller (Available)
Hardening Medium	Water, oil, salt, alkali, etc.
Hardening Way	Semi-automatic, Full automatic.
Upgraded	CNC system or PLC control system
Protection Function	Over voltage, over current, short circuit, water shortage, phase loss, water temperature alarm, etc.
Warranty	One year technical support and service

ROCHO technical team can customize the induction heating power supply for special purposes according to customer requirements, and design capacitors, frequencies and induction coils according to the metal workpiece to be heated and heating requirements to achieve the best heating effect.
When you need to consult or order machine, please provide the following information:
(1) the local industrial voltage;
(2) the name and material of the product to be processed;
(3) the required process: heating, brazing, hardening, melting or annealing;
(4) the size of the product to be processed, such as diameter and length and if drawings can be provided.

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