Induction Heating Ball Head Quenching Machine are key equipment in automotive parts manufacturing, specially designed for surface and local quenching of ball head pins (such as suspension system ball heads and steering knuckle ball heads) to improve their wear resistance, fatigue strength, and load-bearing capacity. The following is a detailed introduction to the equipment’s composition, technical characteristics, and selection guide:
I. Core Components of the Equipment
| Module | Functional Description |
|---|---|
| Induction Heating Power Supply | High-frequency/ultra-audio frequency power supply (IGBT or MOSFET), power range 50-200kW, frequency 20-200kHz, precisely adapted for heating complex geometries of ball heads. |
| Quenching Machine Tool | Multi-axis robotic arm or turntable structure, integrated with contour-following inductors, precision positioning fixtures, and quenching medium spraying systems. |
| Cooling System | Dual-circulation cooling device (internal circulation for power supply and coils, external circulation for temperature control of quenching liquid). |
| Control System | CNC or PLC+HMI control, supporting process programming, temperature closed-loop feedback, and process data traceability. |
II. Technical Features and Advantages
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High-Precision Heating and Quenching
Contour-Following Inductor Design:
Customized copper coils (e.g., spiral or multi-turn) tailored to ball head geometry ensure precise matching of heating zones and hardened layer depths (typically 1-3mm), with hardness gradient controlled at HRC 55-62.
Multi-Axis Linkage Control:
Robotic arm-driven inductors dynamically scan along ball head surfaces (speed 0.5-5mm/s) to prevent local overheating or under-quenching. -
Intelligent Process Control
Closed-Loop Temperature Control System:
Real-time infrared temperature monitoring (±5℃ accuracy) dynamically adjusts power and scanning speed to maintain stable austenitizing temperatures (e.g., 850-900℃).
Adaptive Frequency Switching:
High frequency (100-200kHz) for shallow hardening of spherical surfaces, ultra-audio frequency (20-50kHz) for deep hardening of necks. -
High Efficiency and Flexibility
Rapid Model Changeover:
Modular fixtures and inductors (quick-release interfaces) enable changeover within ≤15 minutes, compatible with various ball head sizes (diameter 20-100mm).
Multi-Station Integration:
Optional tempering stations (inductive or furnace type) enable continuous quenching-tempering processes with cycle times ≤30 seconds/piece. -
Reliability
Fault Self-Diagnosis:
Real-time monitoring of water pressure, flow rate, and insulation status. Automatic shutdown and alarm for abnormalities. MTBF ≥6000 hours.
III. Typical Technical Parameters
| Parameter | Range | Application Scenarios |
|---|---|---|
| Power Supply Power | 80-150kW (high frequency), 50-100kW (ultra-audio frequency) | Passenger car ball heads, commercial vehicle heavy-duty ball heads |
| Frequency Range | 20-200kHz (adjustable) | Hardened layer 1-3mm, complex surface heating |
| Processing Accuracy | Positioning error ≤0.1mm, hardness deviation ≤±2 HRC | High-precision transmission components |
| Cooling Medium | Water-based quenching fluid (PAG), polymer solution, or fast quenching oil | Minimizing deformation and cracking |
| Production Cycle | 20-40 seconds/piece | Production lines with 300,000-500,000 annual output |
IV. Selection and Usage Recommendations
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Clarify Process Requirements:
- Ball head material (medium carbon steel, 40Cr, 20MnTiB, etc.), hardened layer depth (1-3mm), annual output (determines automation level).
- Special requirements: Full quenching, local hardening, or combined processes (e.g., carburizing + induction quenching).
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Key Configuration Priorities:
Multi-Axis Robotic Arm: Essential for complex geometries to ensure uniform heating.
Dual-Medium Quenching System: Rapid switching between water/oil to balance hardness and deformation.
Process Database: Stores parameters for quick recall of different ball head models. -
Maintenance and Cost Control:
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Daily check quenching fluid concentration (using refractometer), monthly clean inductor scale.
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Use domestic consumables (e.g., magnetic conductors, insulation sleeves) to reduce long-term costs.
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Format Notes:
- Maintained original Chinese numbering style (一，二，三，四) translated as Roman numerals (I, II, III, IV).
- Preserved table structures and technical terminology consistency.
- Enhanced readability with bold headings and indentation for sub-points.
