Roll Induction Quenching System
As core equipment in the metallurgical industry, roll quenching complete sets of equipment are specifically designed for surface and deep induction quenching of cold/hot rolling rolls. This process enhances their wear resistance, fatigue strength, and spalling resistance, thereby extending the service life of the rolls. 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 | Medium-frequency/ultra-audio frequency power supply (IGBT), power range 500-3000kW, frequency 0.5-10kHz, suitable for deep heating of large-dimension rolls (diameter 200-1500mm). |
| Quenching Machine Tool | Heavy-duty gantry or horizontal structure, integrated with roll rotation drive (0-50rpm), multi-axis inductor movement (XYZ three directions), and high-pressure quenching medium spraying system. |
| Cooling System | Closed dual-circulation cooling (internal circulation: water cooling for power supply and inductor; external circulation: constant temperature control for quenching liquid), equipped with high-flow pump sets (≥200m³/h). |
| Control System | Industrial-grade PLC, supporting coordinated control of multiple parameters such as roll rotation speed, heating power, and spraying flow rate, with real-time data storage and traceability. |
II. Technical Features and Advantages
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Deep and Uniform Quenching
Low-Frequency High-Power Design:
Using 0.5-3kHz medium-frequency power supply, the penetration depth can reach 10-30mm, meeting the requirement for a 5-20mm hardened layer on the roll surface (hardness HRC 55-65).
Segmented Scanning Quenching:
The inductor moves axially along the roll in segments (speed 0.1-2mm/s), combined with rotational movement, to ensure a gentle hardness gradient (transition zone ≤1mm/HRC). -
High-Precision Control
Closed-Loop Temperature Feedback:
Multi-channel infrared thermometers monitor the roll surface temperature in real time (±10℃ accuracy), dynamically adjusting power and movement speed to avoid local overheating or under-quenching.
Contour-Following Inductor:
Customized rectangular or arc-shaped coils based on roll profiles (flat rolls, grooved rolls) ensure uniform magnetic field distribution (energy density deviation ≤5%). -
High Efficiency and Reliability
Continuous Operation Capability:
Supports 24/7 continuous operation, with single roll processing time of 1-4 hours (depending on size and layer depth), and daily processing of 3-6 rolls (length ≤6m).
Fault Redundancy Design:
Parallel dual-power modules and backup cooling pump sets ensure a mean time between failures (MTBF) ≥10,000 hours. -
Energy Saving and Environmental Protection
Zero-Discharge Treatment:
Closed-loop quenching liquid circulation + oil mist collection device complies with ISO 14001 environmental standards.
III. Typical Technical Parameters
| Parameter | Range | Application Scenarios |
|---|---|---|
| Power Supply Power | 1000-2500kW (medium frequency), 500-1500kW (ultra-audio frequency) | Cold rolling rolls (high hardness), hot rolling rolls (thermal fatigue resistance) |
| Frequency Range | 0.5-10kHz (adjustable) | Hardened layer 5-20mm, roll surface width ≤2000mm |
| Roll Dimensions | Diameter 200-1500mm, length ≤10m | Strip mills, section mills, universal mills |
| Hardness Uniformity | ≤±3 HRC | High-precision rolling production |
| Energy Consumption | 300-500 kWh/ton (depending on layer depth) | Large steel plants, roll repair centers |
V. Selection and Usage Recommendations
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Clarify Process Requirements:
- Roll material (e.g., 86CrMoV7, high-chromium cast iron), hardened layer depth (5-20mm), and roll surface hardness gradient requirements.
- Production mode: new roll manufacturing vs. old roll repair, continuous operation duration.
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Key Configuration Priorities:
High-Power Low-Frequency Power Supply: Ensure deep heating capability (e.g., 1000kW/1kHz).
Multi-Axis CNC Machine Tool: Support contour quenching for complex roll profiles.
Dual-Medium Quenching: Switching function between water (fast cooling) and polymer (slow cooling to prevent cracking). -
Maintenance and Cost Control:
- Inspect the inductor insulation layer and copper tube wall thickness monthly, and replace aging capacitor banks annually.
- Use domestic quenching liquids (e.g., PAG) instead of imported brands to reduce operating costs.
Grammar and Format Notes:
- Standardized technical terminology (e.g., “medium-frequency,” “contour-following inductor”) for industry accuracy.
- Maintained logical hierarchy with Roman numerals (I, II, III, V) and clear table structures.
- Optimized sentence flow for readability while preserving technical details.
