Gear Hardening system

Solid-State IGBT Drive Circuit

ROCHO induction hardening system is equipped with a digital all-solid-state induction heating power supply, IGBT drive circuit, and automatic frequency tracking to achieve application matching precise hardening and better heating uniformity.

Principle Of Gear Hardening System

When the workpiece is put into the inductor charged with an alternating current of a certain frequency, an alternating magnetic field will be generated around it. The electromagnetic induction of alternating magnetic field leads to the generation of closed induced current—eddy current, within the workpiece.

The higher the current frequency, the greater the current density difference between the surface layer and the inside of the workpiece, and the thinner the heating layer. After the temperature of the heating layer exceeds the critical point temperature of the steel, the surface hardening can be realized by rapidly cooling.

After hardening, the gear surface will bear large internal compressive stress, and the workpiece will possess high anti-fatigue performance and breaking strength, good hardness, and is not easy to wear and deform.

Automatic Scanning System

High-frequency gear hardening system uses PLC system and variable frequency system to realize the positioning and scanning of metal work pieces. It has the functions of continuous hardening, simultaneous hardening, sectionally continuous hardening, sectionally simultaneous hardening, etc.

Automatic Feeding System
High-frequency hardening system has a CNC system and an automatic feeding system. The equipment does not require manual operation in the hardening process, and can automatically complete the hardening process, with high production efficiency and low labor intensity. The machine has the characteristics of intelligence, automation, labor cost saving, high production efficiency, etc.

Hardening Process Programming
The numerical control system of gear hardening equipment can compile and store various hardening process programs according to the heating requirements of different metal workpieces. The machine adopts human machine interface and PLC electronic control system, allowing operators to use touch screen to set parameters (including part number, counter, heating power, heating time, etc.), with high control accuracy and automaticity.

Precise Temperature Control
The gear hardening system is equipped with an infrared temperature detector, the temperature in the heat treatment process can be controlled, the heating quality is satisfying, and the depth of hardened layers is consistent, ensure the high quality of final production.

All-Round Protection Functionl
Gear hardening system, matching high frequency induction heating power supply, which has multiple protection functions including over-current protection, water shortage protection, over-heat protection, over-voltage protection, short-circuit protection, phase failure protection and other alarm functions. It will automatically alarm in case of faults, greatly improving the reliability of the equipment.

Safe Operation And Maintenance

High-frequency gear hardening system adopts integrated design and fully enclosed protective cover in the structure with beautiful and elegant appearance, simple and safe equipment operation and convenient maintenance and repair. The machine tool adopts an integral welded bed, which has good rigidity, thermal stability and vibration resistance.

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

Power Output	15kW-160kW
Power Supply	380-480V, Three phase, 50Hz/60Hz
Output Current	200A-6000A
Output Frequency Range	30-80kHz
Work Piece Type	Hardening of various gears, shafts, camshaft, crankshaft, spline shaft, crane wheel, pins, cylinder liner etc.
Duty Cycle	100%
Work Piece Max Length	2500mm
Work Piece Max Diameter	1200mm
Work Piece Max Weight	500kg
Scanning Length	X:200mm, Y:300mm, Z:1500mm
Heating Speed	100mm/seconds
Hardening Temperature	100-1900℃ adjustable
Cooling Water	10.6Mpa 4L/min
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	Tooth by tooth gear hardening, continuous hardening, overall hardening.
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
Dimensions	Customized full automatic induction hardening system

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.

Name:

*Email:

Phone:

*Inquiry: