Engine Valve Stem Induction Quenching System
As core equipment for manufacturing key engine components, valve stem quenching complete sets of equipment are specifically designed for surface or local induction quenching of valve stems (diameter 5-15mm, length 80-150mm). This process enhances their wear resistance, high-temperature oxidation resistance, and fatigue strength. The following details the equipment’s composition, technical features, and selection guidelines:
I. Core Components of the Equipment
| Module | Functional Description |
|---|---|
| Induction Heating Power Supply | High-frequency/ultra-audio frequency power supply (IGBT or MOSFET), power 50-200kW, frequency 50-200kHz, suitable for precise heating of slender rods. |
| Quenching Machine Tool | Multi-station turntable or linear structure, integrated with automatic valve loading, contour-following inductor positioning, rotational drive (100-500rpm), and quenching medium spraying system. |
| Cooling System | Dual-circulation cooling (internal circulation for power supply and coils; external circulation for constant temperature control of quenching liquid), equipped with precision flow control valves (±2% accuracy). |
| Control System | PLC + touchscreen control, supporting process parameter storage, closed-loop temperature feedback (infrared temperature measurement), and production data traceability (MES integration). |
II. Technical Features and Advantages
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High-Precision Local Quenching
Contour-Following Inductor Design:
Multi-turn spiral coils or U-shaped focusing coils match the geometric dimensions of valve stems (diameter 5-15mm) to achieve hardened layer depths of 0.5-2mm (hardness HRC 50-58).
Rotational Heating + Spray Quenching:
Valves rotate at a constant speed (200-400rpm) while moving axially (speed 1-5mm/s) to ensure circumferential hardness uniformity (deviation ≤±2 HRC). -
Intelligent Process Control
Closed-Loop Temperature Control System:
Infrared thermometers monitor stem surface temperature in real time (±5℃ accuracy), dynamically adjusting power and movement speed to maintain stable austenitizing temperatures (850-900℃). -
High Efficiency and Flexibility
Multi-Station Parallel Operation:
Turntable design (4-6 stations) enables simultaneous heating, quenching, cooling, and unloading, with a production cycle ≤10 seconds/piece.
Rapid Model Changeover:
Modular inductors and fixtures (quick-release interfaces) allow changeover within ≤5 minutes, compatible with multiple valve specifications (diameter ±2mm variation). -
Energy Efficiency and Reliability
Energy Optimization:
High-frequency power supply efficiency ≥85%, standby power consumption ≤1kW, and low energy consumption of 0.5-1.2 kWh/piece.
Fault Self-Diagnosis:
Real-time monitoring of water pressure, flow rate, and insulation status, with automatic shutdown and alarm for abnormalities.
III. Typical Technical Parameters
| Parameter | Range | Application Scenarios |
|---|---|---|
| Power Supply Power | 80-150kW (high frequency), 50-100kW (ultra-audio frequency) | Passenger vehicle valves, commercial vehicle diesel engine valves |
| Frequency Range | 50-200kHz (adjustable) | Hardened layer 0.5-2mm, stem length ≤150mm |
| Processing Accuracy | Coaxiality error ≤0.05mm, hardness deviation ≤±1.5 HRC | High-precision engine valves |
| Cooling Medium | Water-based quenching liquid (PAG), fast quenching oil, or nitrogen mist quenching | Reducing deformation of slender rods (straightness ≤0.1mm/m) |
| Production Cycle | 8-12 seconds/piece | Production lines with 2,000,000-5,000,000 annual output |
IV. Selection and Usage Recommendations
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Clarify Process Requirements:
- Valve material (stainless steel, heat-resistant alloy), hardened layer depth (0.5-2mm), stem diameter, and length-diameter ratio.
- Production mode: new valve manufacturing vs. refurbishment, and compatibility with multi-variety production.
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Key Configuration Priorities:
High-Frequency Precision Power Supply: Ensure shallow quenching accuracy (e.g., 100kW/150kHz).
Multi-Axis Positioning System: Robotic arm or servo drive to guarantee valve rotation coaxiality.
Dual-Medium Quenching: Switching function between water (fast cooling) and polymer (slow cooling to prevent deformation). -
Maintenance and Cost Control:
- Daily check of quenching liquid concentration (using a refractometer), monthly cleaning of inductor scale.
- Use domestic inductors and consumables (e.g., magnetic conductors) to reduce long-term costs.
Grammar and Format Notes:
- Standardized technical terms (e.g., “coaxiality,” “nitrogen mist quenching”) for industry accuracy.
- Maintained logical hierarchy with clear section numbering and table structures.
- Optimized sentence structure for readability while ensuring technical rigor.
