Heating device and method for special gear rack

Abstract

The present invention relates to a heating device and method for special gear racks, and the device mainly includes an inductor, a burner head, a fixture, a bracket, a mobile transformer, an induction power supply, and a flame heating device. The burner head is fixed to the bracket by a fixture, and the relative position is adjustable, and the bracket is connected to the mobile transformer. The heating device and method first heat the metal within the hardened layer depth of the target workpiece to the Curie point temperature to demagnetize it by flame heating, and then treat the workpiece by electromagnetic heating so that the depth of the heated layer reaches the required treatment temperature. Using the device and method of the present invention to heat special gears with a large hardening depth is conducive to precise control of the heating depth by electromagnetic heating, and the heat transmission energy distribution of the material in a hot state is more uniform, which reduces the internal stress of the workpiece and improves the heating quality. At the same time, the geometric design difficulty and precision requirements of the electromagnetic inductor are reduced, which is beneficial to expanding production.

Description

Technical Field

[0001] The invention relates to the field of heat treatment of parts, and in particular to a heating device and method for special gear racks. Background Art

[0002] A rack railway is a mountain railway that has a special rack placed on the sleeper in the middle of the ordinary track. The locomotive running on the rack railway is equipped with one or more gears that mesh with the rack. In this way, the locomotive can overcome the problem of insufficient adhesion and pull the train up a steep slope with a gradient of up to 48%.

[0003] Using rack trains as sightseeing vehicles, especially in mountainous scenic spots, will gradually become a future development trend, enhance cultural tourism development, and have a positive impact on future development. The gear rack of the rack train is an important part for transmitting loads, and it needs to be strengthened. The special gear rack in the rack train has a large modulus, a large load and a large hardening depth requirement. The current heating method is mainly flame heating, which transfers heat inward through the surface of the gear rack. However, flame heating takes longer time. At the same time, it is difficult to control the boundary of the heating layer inside the workpiece when using flame heating, and it is difficult to control the internal quality. Electromagnetic heating is a fast and easy-to-automatically control heating method that can be used for heating large parts. However, for gear rack workpieces with deeper hardening requirements, one-time heat penetration is not easy to achieve, and the design requirements and manufacturing accuracy of the sensor are high. In addition, when the ferromagnetic material is electromagnetically heated to the Curie point temperature, the material properties will change suddenly, and the heating is likely to cause the surface temperature to be too high, the internal temperature uniformity is poor, and quality problems will occur.

[0004] Therefore, in order to solve the above problems, a device and method for simultaneously using flame heating and electromagnetic heating are proposed. Summary of the invention

[0005] In view of the above problems, the purpose of the present invention is to provide a heating device and method for special gear racks, using a flame heating device to preheat the gear rack to be processed, so that the temperature within the required hardening depth reaches the Curie point temperature, and the material loses magnetism; then electromagnetic heating is used to heat the hardened layer depth, and the frequency is controlled to control the heat penetration depth of electromagnetic heating, so that the hardened layer depth is fully heated at one time, and the heating speed is controlled by adjusting the power. This heating device and method effectively improves the temperature uniformity of the heating layer, reduces the temperature gradient, and improves the heating quality.

[0006] The technical solution adopted by the present invention is as follows:

[0007] The heating device for special gear rack proposed in the present invention mainly includes an inductor, a burner head, a fixture, a bracket, a mobile transformer, an induction power supply, and a flame heating device, and is characterized in that:

[0008] The burner head is connected to the fixed frame; the fixer is fixed on the bracket, and the relative position of the two is adjustable; the bracket is fixed on the mobile transformer, and the relative position of the two is also adjustable; during operation, the burner head and the fixed frame remain relatively still, and the bracket and the moving component of the mobile transformer remain relatively still.

[0009] The inductor is fixed on the moving component of the moving transformer, and the moving transformer is connected to the induction power supply through a cable; the induction power supply provides energy for electromagnetic heating.

[0010] The burner head is connected to the flame heating device to perform flame heating on the workpiece.

[0011] Furthermore, a slot is provided on the plate surface of the bracket, and the fixer can move up and down in the slot of the bracket.

[0012] Furthermore, the fixing frame has a hollow circular hole structure in the middle and a bolt fixing hole on the top, and the burner head is fixed in the fixing device by means of structures such as bolts or screws.

[0013] A heating method for a special gear rack, characterized in that the heating method mainly comprises the following steps:

[0014] S1. Determine the hardened layer depth d0 and equipment parameters:

[0015] Determine the hardened layer depth d0 according to processing requirements and drawings; determine the parameters that the induction power supply can provide, including the moving transformer moving speed and power range; determine the parameters of the flame heating device;

[0016] S2, calculate the energy required for flame heating, determine the time t1 required for flame heating to the Curie point temperature, and calculate the frequency required for direct electromagnetic heating to the depth d0;

[0017] S3. Determine the moving speed v1 of flame heating:

[0018] According to the above steps, the workpiece is heated by flame until it loses magnetism at depth d0, and the moving speed v1 required for flame heating is determined, and the value of v1 is within the adjustable range of the mobile transformer;

[0019] S4. According to v1, determine the heating power p0 of the electromagnetic heating equipment:

[0020] The moving speed of the inductor is the same as that of the combustion head. Based on v1 and the structure of the inductor, the power p0 used by the induction power supply in the electromagnetic heating device is calculated;

[0021] S5. Adjust the distance between the flame nozzle and the sensor to d1 according to the flame width;

[0022] S6. Run the flame heating device, and measure the gear surface temperature after the flame heating device moves a corresponding full distance;

[0023] S7. Turn on the flame heating device and the electromagnetic heating device at the same time to process the workpiece to be processed.

[0024] Compared with the prior art, the present invention has the following beneficial effects:

[0025] 1. Use flame heating to completely demagnetize the hardened layer within the depth of the size, and make the electromagnetic properties consistent, which is conducive to the accurate control of the electromagnetic heating depth. The heat energy distribution in the hot state is more uniform, which improves the uniformity of temperature distribution and improves the heating quality.

[0026] 2. Preheating by flame heat transfer can greatly reduce the temperature gradient inside the workpiece, effectively reduce the tensile stress inside the gear rack, and improve the quality of heat treatment.

[0027] 3. The method is simple and easy to implement, which is beneficial to expanding production and implementing technological improvements and upgrades.

[0028] 4. The combination of flame heating external heat source input and electromagnetic heating internal heat source heating can effectively avoid surface temperature overheating, expand the effective preheating area, and control processing deformation.

[0029] 5. First, the material is demagnetized by heating, and then heated by electromagnetic method. This can reduce the geometric design difficulty and precision requirements of the electromagnetic heating sensor, while improving the quality, which is beneficial to the expansion of production. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The accompanying drawings are used to provide a further understanding of the present invention and constitute a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention and do not constitute a limitation of the present invention. In the accompanying drawings:

[0031] Figure 1 It is a schematic diagram of the overall structure of the device of the present invention;

[0032] Figure 2 It is a schematic diagram of the support structure of the device of the present invention;

[0033] Figure 3 is a schematic diagram of a fixer in the device of the present invention;

[0034] Figure 4Schematic diagram of the process of the present invention.

[0035] Among them, the figure numerals are: 1-inductor, 2-combustion head, 3-fixer, 4-bracket, 5-mobile transformer, 6-induction power supply, 7-flame heating equipment. DETAILED DESCRIPTION

[0036] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0037] It should be noted that, in the description of the present invention, the terms "up", "down", "top", "bottom", "one side", "the other side", "left", "right", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not mean that the device or element must have a specific orientation, be constructed and operated in a specific orientation.

[0038] See attached Figures 1 to 3 , gives a specific structure of an embodiment of the heating device for special gear racks proposed by the present invention, including an inductor 1, a burner head 2, a fixture 3, a bracket 4, a mobile transformer 5, an induction power supply 6, and a flame heating device 7, characterized in that:

[0039] The burner head 2 is connected to the fixing frame 3 , and the fixing frame 3 has a hollow circular hole structure in the middle and a bolt fixing hole on the top. The burner head 2 is fixed in the fixture by bolts or screws, and the position of the burner head 2 can be adjusted forward and backward in the fixing frame 3 .

[0040] The holder 3 is fixed on the bracket 4, and the relative position of the two is adjustable; the plate surface of the bracket 4 has a slot, and the holder 3 can move up and down in the slot of the bracket 4. The bracket 4 is fixed on the moving component of the moving transformer 5, and the relative position of the two is also adjustable; during the working process, the burner head 2 and the fixing frame 3 remain relatively still, and the bracket 4 and the moving component of the moving transformer 5 remain relatively still.

[0041] The inductor 1 is fixed on the moving component of the mobile transformer 5, and the mobile transformer 5 is connected to the induction power supply 6 through a cable; the induction power supply provides energy for electromagnetic heating. The burner head 2 is connected to the flame heating device 7 to perform flame heating on the workpiece.

[0042] See attached Figure 4 As shown, a heating method for a special gear rack is provided, which comprises the following steps:

[0043] S1. Determine the hardened layer depth d0 and equipment parameters:

[0044] Determine the hardened layer depth d0 according to processing requirements and drawings; determine the parameters that the induction power supply can provide, including the moving transformer moving speed and power range; determine the parameters of the flame heating device;

[0045] S2. Calculate the energy required for flame heating, determine the time t1 required for flame heating to the Curie point temperature, and calculate the frequency required for direct electromagnetic heating to a depth of d0; the calculated values ​​are calculated using heat transfer and electromagnetic related formulas;

[0046] S3. Determine the moving speed v1 of flame heating:

[0047] According to the above steps, the workpiece is heated by flame until it loses magnetism at depth d0, and the moving speed v1 required for flame heating is determined, and the value of v1 is within the adjustable range of the mobile transformer;

[0048] S4. According to v1, determine the heating power p0 of the electromagnetic heating equipment:

[0049] The moving speed of the inductor is the same as that of the combustion head. Based on v1 and the structure of the inductor, the power p0 used by the induction power supply in the electromagnetic heating device is calculated;

[0050] S5. Adjust the distance between the flame nozzle and the sensor to d1 according to the flame width:

[0051] S6. Run the flame heating device. After the flame heating device moves a corresponding full distance, measure the gear surface temperature:

[0052] S7. Turn on the flame heating device and the electromagnetic heating device at the same time to process the workpiece to be processed.

[0053] The difference between the heating device and method of the special gear rack of the present invention and the device and method in the prior art is that: the present invention first uses flame heating to preheat the gear rack to be processed, so that it reaches the Curie temperature and demagnetizes, which can increase the heat penetration depth of electromagnetic heating at the same frequency, and directly heat the material in the depth of the hardened layer to the required temperature by a one-time heat penetration method. Flame heating and electromagnetic heating are coordinated to perform scanning heating treatment on the tooth profile from bottom to top. Using the device and method of the present invention to process the special gear rack can more accurately control the heating depth of the tooth profile at each position, improve temperature uniformity, and reduce the temperature gradient in the workpiece at the same time, effectively reducing the tensile stress generated inside the gear rack. Using the device and method for processing can also effectively avoid overheating of the surface temperature, expand the effective preheating area, control processing deformation, and improve quality. The method can reduce the geometric design difficulty and precision requirements of the electromagnetic heating sensor, the method is simple and easy to implement, and is beneficial to expanding production and implementing technical improvements and upgrades.

[0054] The embodiments described above are merely descriptions of preferred implementation modes of the present invention, and are not intended to limit the scope of the present invention. Without departing from the design spirit of the present invention, various modifications and improvements made to the technical solutions of the present invention by ordinary technicians in this field should all fall within the protection scope determined by the claims of the present invention.

Claims

1. A heating method for a heating device for a special gear rack, mainly comprising an inductor, a burner head, a fixture, a bracket, a mobile transformer, an induction power supply, and a flame heating device, characterized in that: The combustion head and the fixture are connected to each other; The fixing device is fixed on the bracket, and the relative position of the two is adjustable; During operation, the burner head and the fixture remain relatively still, and the bracket and the moving member of the moving transformer remain relatively still; The bracket is fixed on the moving component of the moving transformer; The inductor is fixed on the moving component on the moving transformer; The mobile transformer is connected to the induction power supply via a cable; The burner head is connected to the flame heating device to perform flame heating on the workpiece; The plate surface of the bracket is provided with a slot hole, and the fixer can move up and down in the slot hole of the bracket; The fixer has a hollow circular hole structure in the middle and a bolt fixing hole on the top; The induction power supply provides energy for electromagnetic heating; The steps include: S1. Determine the hardened layer depth d0 and equipment parameters: Determine the hardened layer depth d0 according to processing requirements and drawings; determine the parameters that the induction power supply can provide, including the moving transformer moving speed and power range; determine the parameters of the flame heating equipment; S2. Calculate the energy required for flame heating: Determine the time t1 required for flame heating to the Curie point temperature, and calculate the frequency required for direct electromagnetic heating to the depth d0; S3. Determine the moving speed v1 of flame heating: According to the above steps, the workpiece is heated by flame until it loses magnetism at depth d0, and the moving speed v1 required for flame heating is determined, and the value of v1 is within the adjustable range of the mobile transformer; S4. According to v1, determine the heating power p0 of the electromagnetic heating equipment: The moving speed of the inductor is the same as that of the combustion head. Based on v1 and the structure of the inductor, the power p0 used by the induction power supply in the electromagnetic heating device is calculated; S5. Adjust the distance between the flame nozzle and the sensor to d1 according to the flame width; S6. Run the flame heating device, and measure the gear surface temperature after the flame heating device moves a corresponding full distance; S7. Turn on the flame heating device and the electromagnetic heating device at the same time to process the workpiece.

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