slewing bearing induction quenching machine
slewing bearing induction quenching machine serve as core machinery in the manufacturing of construction machinery, wind power equipment, and heavy-duty equipment. Specifically designed for induction quenching of slewing bearing raceways, gear rings, and contact surfaces, this equipment enhances their load-bearing capacity, fatigue resistance, and wear resistance. Below is a detailed breakdown of 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 200–2000kW, frequency 0.5–30kHz, suitable for large slewing bearings with diameters of Φ500–5000mm. |
| Quenching Machine Tool | Heavy-duty gantry or vertical structure, integrated with slewing bearing rotation drive (0.1–5rpm), multi-axis inductor movement (XYZ three directions, ±0.1mm accuracy), and spray cooling system. |
| Cooling System | Closed dual-circulation cooling (internal circulation: water cooling for power supply and coils; external circulation: constant temperature control for quenching liquid), flow rate ≥100m³/h, pressure 0.3–0.8MPa. |
| Intelligent Control System | Industrial-grade PLC system, supporting multi-dimensional coordinated control of process parameters (power, frequency, movement speed), with real-time data storage and MES integration. |
II. Technical Features and Advantages
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Large-Dimension Deep Quenching
Low-Frequency High-Power Design:
Utilizes 0.5–10kHz medium-frequency power supply with a penetration depth of 10–30mm, meeting the requirement for a 5–20mm hardened layer in slewing bearing raceways (hardness HRC 55–62).
Segmented Scanning Quenching:
Inductors heat raceways in circumferential segments (speed 0.5–3mm/s) while the workpiece rotates (0.5–2rpm), ensuring a gentle hardness gradient (transition zone ≤1mm/HRC). -
High Precision and Uniformity
Closed-Loop Temperature Control:
Multi-channel infrared thermometers monitor raceway surface temperature in real time (±10℃ accuracy), dynamically adjusting power and movement speed to avoid local overheating or under-quenching.
Contour-Following Inductors:
Customized rectangular or arc-shaped coils based on raceway cross-sections (arc, trapezoidal) ensure magnetic field uniformity with a deviation ≤5%. -
High Efficiency and Flexibility
Multi-Station Integration:
Optional tempering stations (inductive or furnace type) enable continuous quenching-tempering processes, with single-piece processing time ranging from 1–6 hours (depending on diameter and layer depth).
Rapid Model Changeover:
Modular inductors and fixtures (hydraulic quick-change interfaces) adapt to slewing bearings with diameters of Φ500–5000mm, with a changeover time ≤30 minutes. -
Energy Efficiency and Reliability
Energy Recovery System:
Waste heat from quenching liquid is recycled via plate heat exchangers for preheating cold water or workshop heating, reducing overall energy consumption by 20%–30%.
Redundant Safety Design:
Parallel dual-power modules and backup cooling pump sets ensure an MTBF (Mean Time Between Failures) ≥12,000 hours.
III. Typical Technical Parameters
| Project | Parameter Range | Application Scenarios |
|---|---|---|
| Power Supply Power | 500–1500kW (medium frequency), 200–800kW (ultra-audio frequency) | Wind power slewing bearings (Φ3000–5000mm), construction machinery turntable bearings (Φ500–2000mm) |
| Frequency Range | 0.5–30kHz (programmable switching) | Hardened layer 5–20mm, raceway width 50–200mm |
| Processing Accuracy | Coaxiality error ≤0.1mm, hardness deviation ≤±2 HRC | High-precision wind power yaw/pitch bearings |
| Cooling Medium | Water-based quenching liquid (PAG), fast quenching oil, or polymer solution | Reducing deformation of large workpieces (flatness ≤0.2mm/m) |
| Production Cycle | 2–6 hours/piece (depending on diameter and layer depth) | Annual production lines of 1000–5000 sets |
IV. Selection and Usage Recommendations
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Process Requirement Analysis:
- Slewing bearing materials (42CrMo4, 50Mn, etc.), hardened layer depth (5–20mm), and raceway geometric complexity.
- Production mode: new part manufacturing vs. old part repair, and compatibility with multi-specifications.
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Key Configuration Priorities:
- High-Power Medium-Frequency Power Supply: Ensures deep heating capability (e.g., 1000kW/3kHz).
- Multi-Axis CNC Machine Tool: Supports contour quenching of complex raceways (e.g., arc raceways of pitch bearings).
- Intelligent Detection: Integrated online hardness and deformation detection to reduce manual sampling costs.
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Maintenance and Cost Control:
- Monthly inspection of inductor copper tube wall thickness and insulation layers; annual replacement of aging capacitor banks.
- Use domestic quenching liquids and magnetic conductors to reduce operating costs (1/2–1/3 the price of imported components).
Grammar and Format Notes:
- Standardized technical terminology (e.g., “contour-following inductors,” “hydraulic quick-change interfaces”) for industry compliance.
- Maintained logical hierarchy with clear section numbering and table structures.
- Optimized sentence flow for technical clarity while ensuring grammatical accuracy.
