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Crankshaft quenching machine

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曲轴淬火机床

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Summary

The crankshaft quenching machine tool is suitable for various crankshaft quenching, and the heating and cooling process parameters of each inductor can be independently set. The quenching machine tool adopts a dedicated thin transformer and power pulse distribution technology, which can ensure that the hardening layer in the circumferential direction of each quenching part is consistent. The independent sensor suspension technology and crankshaft clamping Assistive technology can be used for quenching a variety of crankshaft products to reduce crankshaft quenching deformation.

Product Details Introduction

The crankshaft quenching machine tool is suitable for various crankshaft quenching, and the heating and cooling process parameters of each inductor can be independently set. The quenching machine tool adopts a dedicated thin transformer and power pulse distribution technology, which can ensure that the hardening layer in the circumferential direction of each quenching part is consistent. The independent sensor suspension technology and crankshaft clamping Assistive technology can be used for quenching a variety of crankshaft products to reduce crankshaft quenching deformation.
Main configuration of crankshaft quenching machine tool
1. The equipment mainly includes: crankshaft quenching machine tool, IGBT medium frequency power supply, quenching liquid circulation cooling device, pure water cooling circulation device (including low-pressure cooling system 0.1-0.2Mpa, 0.6-0.8Mpa high-pressure cooling system), electrical control system, chiller unit, etc; The equipment can perform journal quenching and fillet quenching on various four and six cylinder engine crankshafts with a length of 500-1500mm.
2. Automatic monitoring and protection of temperature, pressure, and flow of quenching liquid and cooling water.
3. The control system has fault protection, indication, and alarm functions.
4. The power chuck, tailstock, and transformer lifting drive mechanism of the quenching machine tool are pneumatic; Loading and unloading mechanism; Adopting a reciprocating dual level trolley, the motor drives the synchronous belt transmission, and the lifting power of the parts is cylinder.
5. Bed head and bed tail: The rotating cylinder power chuck is clamped, and the rotation is driven by a servo motor. At the same time, the position of the tail seat can be electrically adjusted to adapt to different lengths of crankshaft quenching.
6. The crankshaft movement system adopts a servo motor and ball screw to drive the crankshaft to move horizontally, and the guide rail adopts a rectangular linear guide rail. 
7. Load feed: The power for load rise and fall is cylinder.
8. The machine tool is equipped with 6-15 sets of load systems (including quenching transformers, capacitors, inductors, etc.), and each set of loads can be switched and operated independently in sequence; The spacing between transformers can be manually adjusted between 0-100mm.
9. The process parameters for load operation can be independently set.
10. The clamping of the crankshaft adopts central hole and end face positioning, and the headstock and tailstock adopt pneumatic self centering power chucks. The clamping process of the crankshaft is automatically completed, and the tailstock can freely expand and contract according to the expansion amount of the crankshaft during the quenching process; The adjustment of the clamping length adopts a screw electric adjustment.
11. The machine tool control system can select Siemens/Mitsubishi/FANUC/PLC+touch screen and other control systems; The various actions of the machine tool have interlocking protection, and the various process parameters of equipment operation (including voltage, current, heating time, cooling time, heating power, frequency, spray flow rate, etc.) have display or setting functions.
12. In addition to overvoltage, overcurrent, phase loss, and water pressure fault protection, the power supply also has voltage limit, current limit protection, minimum value protection, incoming line voltage too high protection, starting current too high protection, and water temperature protection. It is also interlocked with the supporting machine tool for protection, and the supporting machine tool cannot be started without the power supply ready.
13. Process parameter monitoring can monitor and record the heating parameters of each heating part. 
Advanced technology adopted by HKCR crankshaft quenching machine tool
Solid state contactless switching technology: Solid state switches are used for switching between workstations.
Power pulse distribution technology: can ensure uniform hardening layer in the circumferential direction of any journal.
Tailstock free floating technology: It can ensure the free elongation of the crankshaft during heating and the free shortening of cooling, reducing the quenching deformation of the crankshaft.
Thin quenching transformer technology: 5 to 15 thin quenching transformers with a capacity of 750kVA and a thickness of 55-75mm can be hung simultaneously on the quenching machine tool.
Independent suspension technology: Each quenching transformer adopts independent suspension, and the distance between any adjacent transformers is adjusted by manual screw to adapt to different crankshaft quenching sizes to ensure the flexibility of the machine tool.
Suspension balance technology: The transformer suspension adopts spring type adjustable balance to ensure good tracking of the induction coil and reduce quenching deformation of the crankshaft.
Machine tool working status and process parameter monitoring: The human-machine interface is used to monitor and display the working status of the machine tool, heating and quenching cooling process parameters (including heating voltage and current, working frequency, heating/cooling time, heating energy, pressure, flow rate, cooling water/quenching liquid temperature, etc.).
More than 90% of the parts and components of the machine tool and power supply are imported branded products.
Compared with imported equipment, this machine tool adopts a modular structure, which is easy to install, easy to maintain, and greatly reduces the floor area
Technical characteristics of quenching machine tools
It can perform fillet quenching and journal quenching on various crankshafts, and has automatic/manual cycling operation modes.
The series of equipment can achieve 1-6 sensors feeding in place each time, and 1-3 sensors heating and water spraying cooling at the same time. The process parameters for heating and cooling of each sensor can be independently adjusted.
The loading, unloading, positioning, clamping, and other actions within the machine tool, as well as the processing process, are automatically controlled by the machine tool.
The machine tool adopts an integral welded bed, which has good rigidity, stability, and vibration resistance.
The machine tool is equipped with maintenance and adjustment channels to facilitate the adjustment and replacement of quenching fixtures and sensors, and to facilitate the cleaning of quenching tanks and the replacement of quenching media.
The touch screen can display and monitor all processing programs and process parameters, system fault diagnosis, and alarm light functions.
The bed head adopts pneumatic self centering power chuck, which can automatically clamp the workpiece, and the tailstock can automatically move on the guide rail to adapt to different workpiece lengths.
Crankshaft positioning method: the center position of the crankshaft is determined by the center of the bed head and tailstock, and the left and right positions of the crankshaft are determined by the end face of the shaft.
The spindle rotation drive of the bed head adopts AC servo drive, with any rotation angle positioning function.
The movement of the drag plate (left and right) is achieved by using an AC servo motor to drive the ball screw. The screw and guide rail are imported products, and the transmission mechanism has good positioning accuracy, wear resistance, rigidity, low-speed motion stability, and vibration resistance. The speed range of the drag plate movement is 0-100mm/s; The slide rail is equipped with a protective cover.
The lifting and lowering of the inductor is driven by an SMC self-locking cylinder and equipped with a buffer device, which has automatic protection functions for power and gas interruption. The lowering of the induction coil has a fast/slow control device, ensuring that the induction coil accurately enters the quenching area without collision in the shortest possible time.
The water, circuit, and air connections between the thin crankshaft special quenching transformer and the inductor are connected using a quick change device. Each quenching transformer is independently suspended, and the spacing between any adjacent transformers is manually adjusted by a screw to adapt to different spacing sizes of crankshaft quenching, ensuring the flexibility of the machine tool; The transformer suspension adopts spring type adjustable balance, ensuring that the inductor has good floating tracking characteristics and minimizing crankshaft deformation.
All cooling water pipes and quenching water pipes of the transformer and induction coil are imported from Sweden, and the quick change joints are original imported products.
The capacitor adopts the full film capacitor produced by GE technology in the United States, with small size and high stability. The capacitor adjustment adopts a fast way.
The power supply adopts internationally advanced IGBT transistor power supply, controlled by DSP, with high power efficiency, low failure rate, and high startup success rate. It has a complete set of protection functions and diagnostic alarm functions. The power supply is equipped with multiple power channels for automatic switching, and the connecting rod shaft diameter quenching has power pulse distribution function to ensure uniform hardening layer in the circumferential direction of the shaft neck; The safety indicators of the intermediate frequency power supply comply with relevant national standards, and the safety protection level is IP65; The medium frequency power supply is a fully sealed structure, and the cabinet is equipped with maintenance lighting and sockets.
The cooling water circulation system adopts softened water circulation cooling, the heating power supply adopts low-pressure cooling, the load system includes quenching transformer, induction coil adopts high-pressure cooling, and each cooling branch is equipped with temperature, pressure, and flow monitoring and protection devices.
The quenching liquid circulation system adopts PAG water-soluble medium, and the quenching branch is equipped with SMC piston type solenoid valves, as well as temperature, pressure, and flow monitoring and protection devices.
The cooling water and quenching circulation system both use efficient stainless steel plate heat exchangers for heat exchange with chillers or user factory circulating cooling water, with strong cooling capacity and high temperature control accuracy, ensuring long-term reliable operation of the equipment and stable quenching quality of the crankshaft; The chiller system is equipped with temperature and pressure monitoring and display devices, which can automatically adjust according to the temperature of the cooling water and quenching liquid.
The entire equipment includes all mechanical, power, and heating load systems, cooling water and quenching liquid circulation systems, and chillers. It can be directly installed on the ground of the user's workshop, eliminating the need for users to configure auxiliary facilities such as water tanks and cooling towers.
The complete set of equipment is subject to a turnkey project.

 

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