Crane Wheel Induction Hardening Machine

Crane Wheel Induction Hardening Machine

A crane wheel induction hardening machine is a device that uses induction heating to harden the surface of crane wheels, which are used to support the weight of heavy machinery. There are two main methods of hardening:?overall hardening?and?scanning hardening.?Overall hardening heats the entire wheel to a high temperature and then quenches it in a liquid tank while scanning hardening heats a local area of the wheel and sprays liquid cooling on it.?Both methods aim to improve the wear resistance and fatigue strength of the crane wheels.?A crane wheel induction hardening machine consists of an induction heating power supply, a water cooling and hardening system, a multi-station hardening machine tool, a manipulator loading and unloading system, and an operating system.

How to do crane wheel induction hardening?

To do a crane wheel induction hardening job, you need to have a crane wheel induction hardening machine and follow the steps below:

- Choose the appropriate hardening method: overall hardening or scanning hardening. Overall hardening is suitable for wheels that need uniform hardness and no soft belt while scanning hardening is suitable for wheels that need local hardness and can tolerate a soft belt at the junction of the beginning and end of quenching.

- Place the crane wheel at the material loading station and use a mechanical arm or a manual hoist to clamp it on the machine table.

- Move the induction coil to the corresponding wheel heating position and turn on the heating power supply.

- When the wheel reaches the hardening temperature, stop the heating power supply and move the induction coil back to standby.

- For overall hardening, put the wheel into the quenching liquid tank for immersion quenching treatment. For scanning hardening, spray liquid cooling on the heated area of the wheel.

- Transfer the wheel to the quenching station and check the hardness result.

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What are the advantages of crane wheel hardening with induction?

Some of the advantages of hardening crane wheels with induction are:

- Selective hardening: Induction allows you to harden only the desired area of the wheel, without affecting the rest of the part. This means that you can machine the other parts of the wheel while hardening only the specific region you want to harden.

- Efficiency: Induction heating only heats the portion of the wheel needed for hardening, resulting in lower energy costs and faster heating cycles. Induction also eliminates the need for a furnace or cooling cycles, making it a more environmentally friendly process.

- Quality: Induction hardening produces a hard, wear-resistant surface that also enhances the fatigue strength of the wheel. By creating residual surface compressive stresses, induction hardening reduces the risk of cracking and distortion. Induction hardening also allows for precise control of the depth and uniformity of the hardened layer, ensuring consistent quality and performance.

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How do I choose the right induction heating power supply?

To choose the right induction heating power supply, you need to consider several factors, such as:

- Your part's material: Different materials have different electrical conductivity and magnetic permeability, which affect how easily they can be heated by induction. Magnetic materials are heated more easily than nonmagnetic materials; metals with high resistivity like steel heat quickly, while low-resistivity metals like copper or aluminum require more heating time.

- Depth of heating penetration: The induced current will be most intense on the surface of your part, and decrease as the depth increases. Larger parts and parts that require thorough heating take more time and power to heat than those that are thin or small.

- Operating frequency: The frequency of the alternating current in the coil affects how deep the heating penetrates the part. Lower-frequency, higher-power systems are generally suited for heating larger parts that require thorough heating. Higher-frequency, lower-power systems are often the right choice for surface heating. As a general rule, the higher the frequency, the shallower the heating of the part.

- Applied power: The output power of your induction heating power supply determines the relative speed at which your part is heated. The mass of the part, rise in temperature, and heat losses from convection and conduction need to be considered. Often, the induction equipment manufacturer can help you make this assessment.

- Rise in temperature required: Induction can generate a significant change in temperature, but more power is needed to accommodate a significant temperature change and will impact your power-supply choice. The rate of temperature change also affects your power-supply choice.

- Coil design: The coil is the part that transfers the electromagnetic energy to the part. The coil design should match the shape and size of the part to ensure efficient coupling and uniform heating. The coil should also allow easy insertion and removal of the part.

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