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Current Location:Product Center > IGBT quenching equipment

IGBT variable frequency induction quenching equipment (medium frequency/ultrasonic frequency/high frequency)

  • Application fields: vertical/horizontal quench machining tool, universal/dedicated quench machining tool, single-station/multi-station quenching, continuous scanning quenching, revolving scanning/rotary scanning quenching, press quenching, atmosphere protection quenching, revolving/static heating quenching and all kinds of induction quenching.
  • Constitution of equipment complex: full-automatic digital IGBT variable frequency parallel-connected induction heating power supply, quench machining tool and auxiliary devices, machining tool CNC control system (Siemens 802/840/industrial personal computer), quality monitoring system, inductor, transformer, capacitor and cooling system, etc.
  • Performance indicators: medium frequency/ultrasonic frequency/high frequency quenching, depth of hardening layer, hardness, appearance, hardening area (shape distribution), distortion and cracks, power factor and energy consumption, etc. all reach the international advanced level.

Variable frequency induction heating power supply

  • Variable frequency self-adaption range of the variable frequency power supply: 50KHZ variable frequency self-adaption; in this frequency range, auto-matching shall be conducted and selection of power supply frequency satisfies requirements of the hardening layer of all the workpieces. 50KHZ frequency width makes a machining tool be able to process workpieces using medium frequency/ultrasonic frequency or using ultrasonic frequency; this technology can save investment for customers and there is no need to adjust the main control panel during workpiece or load change.

  • Variable frequency power supply auto-matching: it is suitable for connection with inductor of multiple types. During the heating process, the variable frequency power supply shall conduct the self-adaption adjustment according to changes in inductor, material and technical parameters and load matching adjustment is simple and rapid.

  • Power automatic adjustment: within the required frequency range, power output of 10-10% is continuous output, and frequency is continuously and automatically adjusted or continuously and automatically adjusted by stages.

  • Powerful resistance to voltage fluctuation: ensure the product processing quality shall not be affected by 360V-440V network voltage fluctuation.

  • High power factor: With the parallel-connected wave cutting technology being adopted and any load being matched, and under the case of a power output from 10% to 100%, the power factors are always higher than 0.93 requiring no individual power compensation device, which not only reduces equipment investment and enables users to cut electric charges together with enhancing power supply capability, reducing higher harmonics, and improving power quality.

  • Intelligent protection system: there is a ground safety protection device installing on the variable frequency power supply. Once the workpiece touches the inductor during the operation process, the grounding protection device shall be activated, and immediately output signals to cut off the power supply to stop the equipment operation and protect the workpiece and the inductor. Diode special protection technology is adopted with no burning-out of the diode permanently. It adopts IGBT topspeed protection technology to prolong the service life of IGBT; and transformer original side/capacitor/output bus arcing protection, etc. Users may also select a customized power protection solution in conformity with all kinds of operating conditions.

Quench machining tool

  • Siemens digital control system is adopted for the machining tool digital control system: the induction quenching process is completed in the manner of full-automatic control and has functions of storage and automatic down-loading of multiple kinds of product procedures and technologies. Different technical parameters of different workpieces can be saved and called through pre-set workpiece number and name. After the workpiece clamping, the operator is able to complete quenching through “one-button operation”. The control system has functions of failure display, diagnosis, alarm and password protection.

  • Machining tool function: the machining tool has functions of setting and real-time display of voltage, current, frequency and power. The machining tool has the function of displaying quench bath temperature and flow. The machining tool has the function of displaying quench bath flow. Once the machining tool conducts the failure alarm, it is able to automatically display the failure type on the KGPSeen. The machining tool is able to monitor energy, and quench bath temperature and flow. The effective monitoring on the whole quenching process is to guarantee the processing quality. All the equipment is equipped with pressure protection and flow protection.

Cooling system

  • Cooling system: the machining tool is equipped with the heat exchange system and meanwhile, it is able to display temperature, pressure and flow of the equipment circulating cooling water and quench bath circulating cooling water. When the above parameters are inconsistent with the working condition requirements, and thus may damage equipment and product quality, it can automatically alarm for reminding.

  • Electrical apparatus element and inductor cooling circulating device: the stainless steel water tank is used and the cooling water tube is copper. It may achieve the monitoring of temperature, flow, and pressure. The system is equipped with self-supporting forced cooling devices (requiring no supply external cooling for the circulating water by users). Its control and operational units are integrated to the control part of quench machining tool.

  • Quench bath circulating cooling device: stainless steel water tank and water tube are adopted. It may achieve the monitoring of temperature, flow, and pressure. The system is equipped with self-supporting forced cooling devices (requiring no supply external cooling for the circulating water by users). Its control and operational units are integrated to the control part of quench michining tool.

Intelligent control system

  • All control and monitoring of the variable frequency power supply and load shall be completed by the integrated digital control system. During the processing process, use the control system to form the closed loop control, track and automatically adjust to achieve the best frequency. The system has perfect safety protection and alarm devices. The load has the independent compensation capacitor and is able to automatically switch for connection.

  • The quenching process monitoring system: the electron energy meter is able to preset the minimum/maximum value in order to control the actual energy transmitted to the workpiece during each heating period and the failure information shall be displayed on the control panel through clear words. For the quench bath temperature monitoring, there is a digital display, which is able to preset the minimum/maximum value, and the failure information shall be displayed on the control panel through clear words. For the quench bath flow monitoring, there is an actual figure display, and different minimum/maximum values can be pre-selected through PLC. The flow is controlled by the hand valve and the failure information shall be displayed on the control panel through clear words.

  • Machining tool control system: the Siemens digital control system is adopted and the industrial touch panel or the industrial personal computer is equipped. Siemens PLC is in an independent control cabinet and is able to provide all the mechanical actions and the process control of the heating function, including: Clear descriptions related to all the prerequisites to starting the quenching operation, operation mode, time control of movable signals, control and records of all the process data, record of all the operation errors, proximity switch control, feed and automatic exit interlocking and error information. When an error occurs to the machining tool working status and power supply interlocking, sudden stop can be conducted immediately and the machining tool shall complete the normal circulation after the error has been eliminated.

    The system has functions of failure alarm and self-diagnosis and is able to inquire the present and historical failures and store 500 pieces of failure information at least. Each piece of failure information is equipped with detailed words for deKGPSiption, including the time of failure occurrence and actual operation value.

    The system is able to store the program data related to 100 types of workpieces at least. Through the communication interface of the control system, all programs can be input into the computer, which facilitates the technical personnel to conduct the program edit and processing not on the machine.

  • Quality monitoring system and quality traceability function; real time monitoring/remote control of operating state; failure self-diagnose/online display and treatment; technology customization and technical parameter control.