A spherical gyratory part induction heating device and method

Abstract

The present application relates to the technical field of metal heat treatment, and particularly relates to a kind of spherical rotary body part induction heating device and method.The device includes base, and the base is provided with centring lifting platform, and the centring lifting platform is provided with inclination adjusting device above, and the inclination adjusting device is provided with rotating platform device above, and the rotating platform device is provided with three-jaw chuck above, and the three-jaw chuck is used to fix spherical rotary body part;Heating device, and the heating device includes high-frequency power supply, and the high-frequency power supply is provided with induction coil support above, and the induction coil support side is provided with induction coil and magnet conductor, and the magnet conductor is located above induction coil, and the induction coil is located above spherical rotary body part, and the induction coil and magnet conductor are used to heat spherical rotary body part together, and the magnet conductor is in the form of "Π".Multi-modal intelligent temperature control system includes temperature acquisition device, central control processor, infrared monitoring scanning system and over-temperature alarm system.The present application significantly improves the comprehensive efficiency of production line, and is convenient for large-scale popularization and application.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of metal heat treatment, in particular to an induction heating device and method for a spherical rotary part. BACKGROUND

[0002] As a core force transmission component of the automobile steering and suspension system, the ball pin plays an important role in connecting key components such as steering knuckles and control arms during vehicle driving. The head of the ball pin directly participates in force transmission and motion guidance and is subjected to impact load from the road, alternating torque generated by steering operation, and continuous friction between components at all times. Such complex working conditions pose strict requirements on the surface performance of the head of the ball pin: on the one hand, excellent wear resistance is required to resist size wear caused by long-term friction and to avoid abnormal noise or precision decline caused by increased fitting clearance; on the other hand, high-strength fatigue resistance is required to cope with stress concentration under high-frequency alternating load and to prevent failure phenomena such as cracks and even breakage – these performances are directly related to the stability of automobile steering and driving safety. Currently, induction heating quenching process is generally used in industrial production to perform surface hardening treatment on the head of the ball pin. This process rapidly heats the surface layer of the workpiece and quenches it through electromagnetic induction principle, can form a hardened layer in a short time, and takes into account treatment efficiency and energy economy, thus becoming the mainstream technical solution in mass production.

[0003] However, due to the spherical geometric characteristics of the ball pin, the electromagnetic field distribution is uneven during induction heating, resulting in inconsistent thickness of the hardened layer, which seriously affects the service life of the product. Although some improved technologies attempt to solve the uniformity problem through complex structure of the profiled coil, such solutions have high manufacturing cost, poor universality, and still cannot fundamentally solve the problem of process parameter collaborative optimization.

[0004] Therefore, it is urgent to develop a device and method for uniformly inducing heating of the head of the ball pin to solve the above problems. SUMMARY

[0005] In view of the above technical problems that the ball pin has uneven electromagnetic field distribution during induction heating due to its spherical geometric characteristics, the thickness of the hardened layer is inconsistent, and the existing profiled coil solution has high manufacturing cost, poor universality, and cannot fundamentally solve the problem of process parameter collaborative optimization, the present application provides an induction heating device and method for a spherical rotary part. The present application mainly utilizes adjustable angle between the axis of the ball pin and the horizontal plane, optimal matching of the rotation speed, and an angle-rotation speed matching database optimized by simulation to realize collaborative control of process parameters, thereby achieving uniform induction heating of the head of the ball pin, ensuring the consistency of the thickness of the hardened layer, reducing the manufacturing cost, improving the universality of the equipment, and further prolonging the service life of the product.

[0006] The technical means adopted by the present application are as follows:

[0007] The spherical rotary part induction heating device comprises a base, a centering lifting platform is arranged above the base, an inclination adjusting device is arranged above the centering lifting platform, a rotating platform device is arranged above the inclination adjusting device, and a three-jaw chuck is arranged above the rotating platform device, and the three-jaw chuck is used for fixing the spherical rotary part.

[0008] The device further comprises a heating device, the heating device comprises a high-frequency power supply, an induction coil support is arranged above the high-frequency power supply, an induction coil and a magnetic conductor are arranged on the side of the induction coil support, the magnetic conductor is arranged above the induction coil, the induction coil is arranged above the spherical rotary part, and the induction coil and the magnetic conductor are used for heating the spherical rotary part together, and the magnetic conductor is in the shape of Π.

[0009] The device further comprises a multi-modal intelligent temperature control system, the multi-modal intelligent temperature control system comprises a temperature acquisition device, a central control processor, an infrared monitoring scanning system and an over-temperature alarm system.

[0010] Further, the base comprises a base body and a mounting platform, the base body comprises four ground anchors fixed to the ground, the mounting platform is arranged above the base body, and the centering lifting platform is connected to the centering lifting platform above the mounting platform.

[0011] Further, the centering lifting platform comprises a first motor, a ball screw spiral synchronous elevator, a centering lifting platform device coupling, a ball screw nut and a lifting platform, the first motor is connected to the ball screw spiral synchronous elevator through the centering lifting platform device coupling, the ball screw spiral synchronous elevator is arranged above the base, the ball screw nut at the top of the ball screw spiral synchronous elevator is connected to the lifting platform, the lifting platform is connected to the inclination adjusting device above the lifting platform, and the first motor drives the lifting movement of the ball screw spiral synchronous elevator through the centering lifting platform device coupling, so as to drive the lifting movement of the lifting platform.

[0012] Furthermore, the tilt adjustment device includes a tilt adjustment device mounting base, a tilt adjustment device support platform, a stepper motor, a bearing housing, a lead screw, a travel block, a connecting rod, a connector, and an angle sensor. The tilt adjustment device mounting base is located above the centering lifting platform. The bearing housing is located above the tilt adjustment device mounting base. One end of the lead screw is rotatably connected to the bearing housing, and the other end of the lead screw is connected to the tilt adjustment device coupling and the stepper motor. The travel block is sleeved on the surface of the lead screw, and the connecting rod is located on the side of the travel block. The tilt adjustment device support platform is located above the connecting rod. The rotating platform device and the angle sensor are located above the tilt adjustment device support platform. The stepper motor drives the lead screw through the tilt adjustment device coupling. The lead screw drives the travel block, and the travel block drives the tilt adjustment device support platform. The connector is located between the tilt adjustment device support platform and the tilt adjustment device mounting base, and the connector serves as the rotation fulcrum of the tilt adjustment device support platform.

[0013] Furthermore, the rotating platform device includes a second motor, a rotating platform device housing, and a rotating platform device connecting foot. The rotating platform device connecting foot is fixed above the tilt adjustment device through a threaded hole. The rotating platform device housing is located above the rotating platform device connecting foot. The three-jaw chuck is located above the rotating platform device housing. A through hole is provided in the upper part of the rotating platform device housing. The second motor is located inside the rotating platform device housing. The output shaft of the second motor is connected to the middle part of the chuck body of the three-jaw chuck through the through hole.

[0014] Furthermore, the cross-section of the connecting leg of the rotating platform device is convex, and the outer shell of the rotating platform device is a cylindrical shell with an opening at the bottom.

[0015] Furthermore, the induction coil is made of a ring-shaped single-turn copper tube, the three-jaw chuck body is made of alloy steel, and a ceramic insulating block is provided on the inner side of the three-jaw chuck.

[0016] This invention also includes an induction heating method for spherical rotating parts, implemented based on the aforementioned induction heating device for spherical rotating parts, comprising the following steps:

[0017] The spherical rotating part is divided into the top region, the middle region, and the transition region to obtain the spherical rotating part to be processed;

[0018] The spherical rotating part to be processed is vertically clamped in a three-jaw chuck. The first motor is started. The first motor drives the ball screw synchronous lift through the coupling of the centering lifting platform device to adjust the height of the lifting platform and adjust the spherical rotating part to be processed to the preset height.

[0019] Adjusting the distance between the spherical rotary body part to be processed and the induction coil according to the specification parameters of the spherical rotary body part to be processed;

[0020] Starting the stepping motor, which drives the lead screw to rotate through the inclination angle adjusting device coupling, and drives the travel block to move along the lead screw, the travel block pushes the inclination angle adjusting device support platform through the connecting rod to adjust the included angle between the spherical rotary body part and the horizontal plane to the preset angle;

[0021] The angle sensor collects the heating angle and transmits it to the central control processor, which calls the angle-rotation speed matching database based on simulation optimization to match the optimal rotation speed of each region, and adjusts the rotation speed of the second motor based on the optimal rotation speed to drive the three-jaw chuck to rotate the spherical rotary body part;

[0022] Starting the high-frequency power supply to generate high-frequency current, which passes through the induction coil, and the induction coil cooperates with the magnetic conductor to generate a magnetic field, which sequentially heats the top region, middle region and transition region of the spherical rotary body part.

[0023] Further, the method further comprises:

[0024] During the heating process, the temperature of the top region, middle region and transition region of the spherical rotary body part is monitored in real time by the infrared monitoring and scanning system to ensure that the target temperature is reached and the temperature uniformity parameters of each region are controlled;

[0025] An overlapping heating zone is set when switching between adjacent regions, and the over-temperature alarm system automatically cuts off power protection when the temperature exceeds the pre-warning temperature.

[0026] Further, the angle-rotation speed matching database is established by the following method:

[0027] Step 1, modeling the spherical rotary body part on the electromagnetic-thermal coupling simulation platform, and setting the reference rotation speed, adjustment rotation speed and maximum iteration number of the model;

[0028] Step 2, dividing the heating angle according to the preset interval, and performing partition simulation on the simulation platform according to the division result;

[0029] Step 3, according to the simulation result, extracting temperature field data, and based on the temperature field data, performing uniformity standard test, the uniformity standard test is according to temperature uniformity index test, if the temperature uniformity index is greater than 15%, it is judged that the temperature uniformity is not up to standard, through thermal imaging analysis to identify the high temperature area position, the high temperature area is located at the bottom of the heating zone adopts V new =V prev +ΔV speed-up strategy, the high temperature area is located at the top of the heating zone adopts Vnew =V prev -ΔV speed reduction strategy, wherein, V new is the updated rotation speed, V prev is the rotation speed before updating, ΔV is the adjustment rotation speed, after adjustment, a new simulation verification is started, after each adjustment, the rotation speed parameter is updated and the iteration counter is incremented, when the number of iterations reaches the maximum number of iterations, the iteration counter is reset and the adjustment rotation speed is halved, the optimal rotation speed parameter corresponding to the entire interval is completed, and an initial angle-rotation speed matching database is constructed.

[0030] If the temperature uniformity index is less than or equal to 15%, it is judged that the temperature uniformity meets the standard, the rotation speed result in the simulation result is recorded, and based on the rotation speed result, an initial angle-rotation speed matching database is constructed, and the calculation formula of the temperature uniformity index is:

[0031] α= (T max - T min ) / T avg

[0032] Wherein, α is the temperature uniformity index, T max is the highest temperature in the simulation area, T min is the lowest temperature in the simulation area, and T avg is the average temperature in the simulation area.

[0033] Step 4, the initial angle-rotation speed matching database is verified on the experimental platform, if the error is less than or equal to 5%, it is confirmed that the initial angle-rotation speed matching database is the angle-rotation speed matching database, if the error is greater than 5%, the model needs to be corrected, and steps 2 to 4 are repeated until the error is less than or equal to 5%.

[0034] Compared with the prior art, the present application has the following advantages:

[0035] 1. The present application divides the spherical body into three characteristic regions by innovative partition heating control strategy, and adopts differentiated inclination-rotation speed parameter combination for optimization heating, effectively solves the problem of uneven electromagnetic field distribution caused by geometric characteristics in traditional induction heating, significantly improves the consistency of hardening layer thickness (temperature uniformity parameter α ≤ 15%), and greatly improves the wear resistance and fatigue resistance of the part.

[0036] 2. The present application adopts modular integrated design, through the coordinated control of inclination adjusting device, centering lifting platform and rotating platform device, and the real-time feedback of multi-modal intelligent temperature control system, realizes the accurate regulation and control of complex space position, and guarantees the heating uniformity.

[0037] Based on the above reasons, the present application can be widely popularized in the field of metal heat treatment. BRIEF DESCRIPTION OF DRAWINGS

[0038] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings needed in the embodiments or prior art description. Obviously, the drawings described below are only some embodiments of the present application, and the drawings can be obtained by those skilled in the art without creative labor.

[0039] Figure 1 It is a schematic diagram of the overall structure of the device of the present application.

[0040] Figure 2 It is a schematic diagram of the local structure of the device of the present application.

[0041] Figure 3 It is a schematic diagram of the inclination position of the device of the present application.

[0042] Figure 4 It is an angle-rotation speed cooperative control logic flow chart of the present application.

[0043] In the figure: 11, three-jaw chuck; 12, second motor; 13, rotating platform device shell; 14, rotating platform device connecting foot; 15, threaded hole; 16, rotating platform device hole; 21, angle sensor; 22, inclination adjusting device support platform; 23, connecting rod; 24, travel block; 25, lead screw; 26, bearing seat; 27, inclination adjusting device coupling; 28, stepper motor; 29, inclination adjusting device mounting seat; 210, connecting piece; 31, lifting platform; 32, ball screw nut; 33, homocentric lifting platform device coupling; 34, ball screw screw synchronous elevator; 35, first motor; 41, base body; 42, mounting platform; 51, induction coil; 52, induction coil support; 53, magnet; 54, high-frequency power supply. DETAILED DESCRIPTION

[0044] In order to make the person skilled in the art better understand the present application, the following will combine the drawings in the embodiments of the present application to clearly and completely describe the technical solutions in the embodiments of the present application. Obviously, the described embodiments are only some embodiments of the present application, not all. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor should belong to the scope of protection of the present application.

[0045] In order to make the objects, technical solutions and advantages of the embodiments of the present application clearer, the following will clearly and completely describe the technical solutions in the embodiments of the present application with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments of the present application. The following description of at least one example embodiment is merely illustrative in nature and is in no way limiting on the application or its applications or uses. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative efforts fall within the scope of the present application.

[0046] It should be noted that the terminology used herein is for the purpose of describing specific embodiments only and is not intended to limit exemplary embodiments according to the present application. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and / or "comprising," when used in this specification, specify the presence of stated features, steps, operations, elements, components, and / or groups thereof, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof.

[0047] The relative arrangement of parts and steps, numerical expressions, and numerical values set forth in the examples are not intended to limit the scope of the present application, unless otherwise specifically stated. It should be apparent that the dimensions of the various parts shown in the drawings are not to scale and are only meant to illustrate the general principles of the application. Techniques, methods, and apparatus known to those of ordinary skill in the relevant art can not be discussed in detail, but should be considered as if the discussion were in place. In all examples shown and discussed herein, any specific value should be interpreted as merely an example, and not as a limitation. Thus, other examples of the exemplary embodiments can have different values. It should be noted that like reference numerals and letters refer to like items in the following drawings, and thus, once an item is defined in one drawing, it need not be discussed further in subsequent drawings.

[0048] In the description of the present application, it should be understood that the orientation words such as "front, back, up, down, left, right", "transverse, vertical, perpendicular, horizontal" and "top, bottom" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, which is only for the convenience of describing the present application and simplifying the description, and does not indicate and imply that the indicated device or element must have a particular orientation or be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the scope of protection of the present application: the orientation words "inner, outer" refer to the inner and outer relative to the contour of each component.

[0049] For ease of description, spatial relative terms such as "above," "over," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation besides the orientation of the device as described in the figures. For example, if the device in the figures is inverted, a device described as "above" or "above" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0050] Furthermore, it should be noted that the use of terms such as "first" and "second" to define components is merely for the purpose of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore should not be construed as limiting the scope of protection of this invention.

[0051] like Figure 1 As shown, this invention provides an induction heating device for a spherical rotating part, including a base, a centering lifting platform 31 on the base, an angle adjustment device above the centering lifting platform 31, a rotating platform device above the angle adjustment device, and a three-jaw chuck 11 above the rotating platform device for fixing the spherical rotating part; the device also includes a heating device, which includes a high-frequency power supply 54, an induction coil support 52 above the high-frequency power supply 54, an induction coil 51 and a magnetic conductor 53 on the side of the induction coil support 52, the magnetic conductor 53 being located above the induction coil 51, and the induction coil 51 being located above the spherical rotating part, the induction coil 51 and the magnetic conductor 53 being used together to heat the spherical rotating part, the magnetic conductor 53 being in the shape of "Π"; the device also includes a multimodal intelligent temperature control system, which includes a temperature acquisition device, a central control processor, an infrared monitoring and scanning system, and an over-temperature alarm system.

[0052] Further, the induction coil 51 adopts a ring-shaped single-turn copper tube, the three-jaw chuck 11 body is made of alloy steel, and the three-jaw chuck 11 inner side is provided with a ceramic insulating block. The magnetic conductor 53 adopts 0.3mm-thick silicon steel sheet lamination, cooperates with an independent inner-outer circulation water cooling system, and ensures that the induction coil 51 working temperature is lower than 60℃. The magnetic conductor 53 is attached to the induction coil 51, and the opening of the magnetic conductor 53 faces the direction of the rotating platform device. The two free ends of the magnetic conductor 53 are connected with the induction coil support 52 respectively. The high-frequency power supply 54 is fixed on the ground, adopts IGBT inverter technology, and has an adjustable output power of 80kW~120kW and a working frequency of 8kHz~10kHz. The induction coil support 52 adopts an insulating material.

[0053] As a preferred mode of the embodiment of the application, the base includes a base body 41 and a mounting platform 42. The base body 41 includes four ground anchors fixed on the ground, adopts high-strength cast iron integral casting, and is provided with four ground anchors at the bottom to ensure the equipment installation stability. The mounting platform 42 is arranged above the base body 41, and the centering lifting platform 31 is connected above the mounting platform 42.

[0054] As a preferred mode of the embodiment of the application, the centering lifting platform 31 includes a first motor 35, a ball screw spiral synchronous elevator 34, a centering lifting platform 31 device coupling, a ball screw nut 32 and a lifting platform 31. The first motor 35 is connected with the ball screw spiral synchronous elevator 34 through the centering lifting platform 31 device coupling, the ball screw spiral synchronous elevator 34 is arranged above the base, the ball screw nut 32 is arranged above the ball screw spiral synchronous elevator 34, the ball screw nut 32 is connected with the lifting platform 31, and the lifting platform 31 is connected with the inclination adjusting device above. The first motor 35 drives the lifting movement of the ball screw spiral synchronous elevator 34 through the centering lifting platform 31 device coupling, so as to drive the lifting movement of the lifting platform 31. The positioning accuracy of the stroke of 0mm~150mm reaches ±0.05mm.

[0055] As Figure 3As shown, in a preferred embodiment of the present invention, the tilt adjustment device includes a tilt adjustment device mounting base 29, a tilt adjustment device support platform 22, a stepper motor 28, a bearing seat 26, a lead screw 25, a stroke block 24, a connecting rod 23, and an angle sensor 21. The tilt adjustment device mounting base 29 is located above the centering lifting platform 31. The bearing seat 26 is located above the tilt adjustment device mounting base 29. One end of the lead screw 25 is rotatably connected to the bearing seat 26, and the other end of the lead screw 25 is connected to a tilt adjustment device coupling. The device comprises a stepper motor 27 and a stepper motor 28. A travel block 24 is sleeved on the surface of the lead screw 25. A connecting rod 23 is located on the side of the travel block 24. A tilt adjustment device support platform 22 is located above the connecting rod 23. A rotary platform device and an angle sensor 21 are located above the tilt adjustment device support platform 22. The stepper motor 28 drives the lead screw 25 through the tilt adjustment device coupling 27. The lead screw 25 drives the travel block 24, and the travel block 24 drives the tilt adjustment device support platform 22 to achieve tilt adjustment of the tilt adjustment device support platform 22. The travel block 24 is covered with insulating material.

[0056] Angle sensor 21 monitors tilt angle changes, with a control accuracy of ±0.1° within the range of 0° to 45°. The device housing is made of aluminum alloy and features an internal automatic lubrication system to ensure long-term operational stability.

[0057] like Figure 2 As shown, in a preferred embodiment of the present invention, the rotating platform device includes a second motor 12, a rotating platform device housing 13, and a rotating platform device connecting foot 14. The rotating platform device connecting foot 14 is fixed above the tilt adjustment device through a threaded hole 15. The rotating platform device housing 13 is located above the rotating platform device connecting foot 14. A three-jaw chuck 11 is located above the rotating platform device housing 13. A through hole is provided in the upper part of the rotating platform device housing 13. The second motor 12 is located inside the rotating platform device housing 13 and extends to the outside of the rotating platform device housing 13. The output shaft of the second motor 12 is inserted into the middle of the chuck body of the three-jaw chuck 11 through the through hole.

[0058] Furthermore, the cross-section of the connecting foot 14 of the rotary platform device is convex, and the outer shell 13 of the rotary platform device is a cylindrical shell with an opening at the bottom. The flange portion can achieve load distribution and increase the contact area, thereby reducing local stress and preventing the three-jaw chuck 11 from loosening or tilting under high-speed rotation or load conditions. The flange portion can limit the radial displacement of the outer shell, and at the same time, it can form a stable support structure after being tightened by threads.

[0059] In a preferred embodiment of the present invention, a connector 210 is provided between the tilt adjustment device support platform 22 and the tilt adjustment device mounting base 29.

[0060] The embodiment of the present application also comprises a spherical rotary part induction heating method, which is realized based on the above-mentioned spherical rotary part induction heating device, and the steps are specifically as follows:

[0061] S1. The spherical rotary part is divided into a spherical top region, a spherical middle region and a transition region.

[0062] Specifically, according to the geometric characteristics of the spherical rotary part to be heated, the spherical rotary part is divided into three heating regions, including:

[0063] A region: the spherical top region, defined as the maximum curvature region above the equatorial plane from the apex, accounting for 20% of the partial surface area of the spherical rotary part; B region: the spherical middle region, defined as the uniform transition annular band adjacent to the upper and lower parts of the equatorial plane, accounting for 50% of the partial surface area of the spherical rotary part; C region: the transition region, defined as the key region including the chamfer surface and the heat affected zone upward from the pin rod connection, accounting for 30% of the partial surface area of the spherical rotary part.

[0064] S2. The spherical rotary part to be processed is vertically clamped in the three-jaw chuck 11, and is fixed by the pneumatic clamping mechanism at a working pressure of 0.4 MPa to 0.6 MPa, while the spatial positions of the heating regions (A region, B region and C region) are positioned in real time by the infrared monitoring scanning system. The first motor 35 is started, and the first motor 35 drives the ball screw 25 screw synchronous elevator through the centering lifting platform 31 device coupling, so as to adjust the height of the lifting platform 31, and adjust the spherical rotary part to be processed to the preset height.

[0065] S3. According to the specification parameters of the spherical rotary part to be processed, the distance between the outer side of the part and the induction coil 51 is accurately adjusted to the optimal coupling distance of 2 mm to 3 mm (adapted according to the diameter specification of the part).

[0066] Wherein, the specification parameters of the spherical rotary part are the outermost diameter of the rotary part.

[0067] Step implementation: the control of the distance is realized by manually adjusting the diameter of the induction heating coil (i.e. the annular coil); the conventional size of the distance is 2 mm to 3 mm, and the distance in actual processing needs to be adjusted accordingly based on the differences of the heated parts.

[0068] S4. Start the stepper motor 28, which drives the lead screw 25 to rotate through the inclination adjustment device coupling 27, drives the travel block 24 to move along the lead screw 25, and drives the inclination adjustment device support platform 22 through the connecting rod 23 to adjust the angle between the spherical body part and the horizontal plane to the preset angle. The angle between the axis of the spherical body part and the horizontal plane is accurately adjusted to the set value within the range of 45°~90°, and the angle sensor 21 feeds back the current angle in real time.

[0069] S5. The angle sensor 21 collects the heating angle and transmits it to the central control processor, which calls the angle-rotation speed matching database based on simulation optimization to match the optimal rotation speed of each region, and adjusts the rotation speed of the second motor 12 based on the optimal rotation speed to drive the three-jaw chuck 11 to rotate the spherical body part.

[0070] The specific method for matching the optimal rotation speed is as follows: according to the preset order control strategy, differential heating treatment is performed on the A zone, B zone and C zone in turn, and the optimal rotation speed of each region (A zone corresponding to a1 inclination + A1 rotation speed, B zone corresponding to b1 inclination + B1 rotation speed, C zone corresponding to c1 inclination + C1 rotation speed) is matched.

[0071] S6. Start the high-frequency power supply 54 to generate high-frequency current, which passes through the induction coil 51, and the induction coil 51 cooperates with the magnetic conductor 53 to generate a magnetic field to heat the top region, middle region and transition region of the spherical body part in turn.

[0072] The heating position adjustment step includes:

[0073] Height adjustment: drive the ball screw 25 mechanism at a feed speed of 4mm / s~5mm / s to adjust the height of the lifting platform 31, so that the center axis of the current heating partition is aligned with the horizontal center of the induction coil 51;

[0074] Spacing adjustment: according to the diameter specification of the part, accurately adjust the spacing between the outer side of the part and the induction coil 51 to the optimal coupling distance of 2mm~3mm;

[0075] Inclination adjustment: drive the lead screw 25 to rotate through the stepper motor 28 of the inclination adjustment device, drive the travel block 24 to move along the lead screw 25, and drive the inclination adjustment device support platform 22 through the connecting rod 23 to adjust the angle between the part axis and the horizontal plane to the set value within the range of 45~90°;

[0076] Rotation speed adjustment: drive the three-jaw chuck 11 through the second motor 12 to rotate the part at a adjustable rotation speed of 20rpm~100rpm;

[0077] S7. During the heating process, the temperatures of the top, middle and transition regions of the sphere are monitored in real time by an infrared monitoring scanning system to ensure that the target temperature (850-900°C) is reached and the temperature uniformity parameters of each region are controlled.

[0078] S8. A 5mm wide overlapping heating band is provided when switching between adjacent regions, and the over-temperature alarm system automatically cuts off power when the temperature exceeds the pre-warning temperature (900°C) to provide protection.

[0079] wherein, as shown in Figure 4 the angle-rotation speed matching database is established by the following method:

[0080] Step 1. On the electromagnetic-thermal coupling simulation platform, model the spherical rotary part, and according to the inclination characteristics of the axis of the spherical rotary part and the horizontal plane, divide the inclination into nine intervals: I zone (45°-50°), II zone (50°-55°), III zone (55°-60°), IV zone (60°-65°), V zone (65°-70°), VI zone (70°-75°), VII zone (75°-80°), VIII zone (80°-85°) and IX zone (85°-90°); set the reference rotation speed V = 50 rpm, the dynamic adjustment rotation speed ΔV (initially 5 rpm) and the maximum iteration number imax = 8 for each interval.

[0081] Step 2. Based on the nine divided angle intervals, independently model and simulate each interval on the simulation platform. When performing the partition simulation, call the corresponding angle partition geometric model, define the material parameters and load the preset power.

[0082] Step 3. According to the simulation results, extract the temperature field data, and based on the temperature field data, perform the uniformity standard test. The uniformity standard test is based on the temperature uniformity index test. If the temperature uniformity index is greater than 15%, it is judged that the temperature uniformity is not up to standard. The high temperature region is identified by thermal imaging analysis. The high temperature region located at the bottom of the heating zone adopts the V new = V prev + ΔV speed-up strategy, and the high temperature region located at the top of the heating zone adopts the V new = V prev - ΔV speed-down strategy, wherein V new is the updated rotation speed, V prev is the updated rotation speed, ΔV is the adjustment rotation speed. After each adjustment, update the rotation speed parameter and increment the iteration counter. When the iteration number reaches the maximum iteration number, reset the iteration counter and halve the adjustment rotation speed. The optimal rotation speed parameters corresponding to all intervals (nine inclination intervals) are completed, and the initial angle-rotation speed matching database is constructed.

[0083] If the temperature uniformity index is less than or equal to 15%, it is determined that the temperature uniformity meets the standard, the speed result in the simulation result is recorded, and an initial angle-speed matching database is constructed based on the speed result, the database supports real-time query and calling, and can be directly embedded into a production line control system to ensure that uniform heating effect can be obtained under different inclination conditions, thereby improving product quality and production efficiency.

[0084] The calculation formula of the temperature uniformity index is:

[0085] α = (T max -T min ) / T avg

[0086] Wherein, α is the temperature uniformity index, T max is the highest temperature in the simulation area, T min is the lowest temperature in the simulation area, and T avg is the average temperature in the simulation area.

[0087] Step 4: The initial angle-speed matching database is verified on an experimental platform, if the error is less than or equal to 5%, it is confirmed that the initial angle-speed matching database is the angle-speed matching database; if the error is greater than 5%, the model needs to be corrected, and steps 2 to 4 are repeated until the error is less than or equal to 5%.

[0088] Finally, it should be noted that: the above embodiments are only used to illustrate the technical solutions of the present application, and not to limit them; although the present application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that: it can still modify the technical solutions recorded in the foregoing embodiments, or make equivalent replacement for part or all of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the scope of the technical solutions of the embodiments of the present application.

Claims

1. A spherical gyrator part induction heating device, characterized by, The device comprises a base, a concentric lifting platform above the base, an inclination adjusting device above the concentric lifting platform, a rotating platform device above the inclination adjusting device, and a three-jaw chuck above the rotating platform device, the three-jaw chuck being used for fixing a spherical body part; The device further comprises a heating device, the heating device comprising a high-frequency power supply, an induction coil support above the high-frequency power supply, an induction coil and a magnetic conductor on the side of the induction coil support, the magnetic conductor being above the induction coil, the induction coil being above the spherical body part, the induction coil and the magnetic conductor being used for heating the spherical body part together, and the magnetic conductor being in the shape of "Π". The device further comprises a multi-modal intelligent temperature control system, the multi-modal intelligent temperature control system comprising a temperature acquisition device, a central control processor, an infrared monitoring scanning system, and an over-temperature alarm system. The inclination adjusting device comprises an inclination adjusting device mounting seat, an inclination adjusting device support platform, a stepping motor, a bearing seat, a lead screw, a travel block, a connecting rod, a connecting piece, and an angle sensor, the inclination adjusting device mounting seat being above the concentric lifting platform, the bearing seat being above the inclination adjusting device mounting seat, one end of the lead screw being rotatably connected with the bearing seat, the other end of the lead screw being provided with the inclination adjusting device coupling and the stepping motor connected therewith, the travel block being sleeved on the surface of the lead screw, the connecting rod being on the side of the travel block, the inclination adjusting device support platform being above the connecting rod, the rotating platform device and the angle sensor being above the inclination adjusting device support platform, the stepping motor driving the lead screw through the inclination adjusting device coupling, the lead screw driving the travel block, the travel block driving the inclination adjusting device support platform, the connecting piece being between the inclination adjusting device support platform and the inclination adjusting device mounting seat, and the connecting piece being the rotation fulcrum of the inclination adjusting device support platform. The rotating platform device comprises a second motor, a rotating platform device shell, and a rotating platform device connecting foot, the rotating platform device connecting foot being fixedly provided above the inclination adjusting device through a threaded hole, the rotating platform device shell being above the rotating platform device connecting foot, the three-jaw chuck being above the rotating platform device shell, a through hole being on the upper part of the rotating platform device shell, the second motor being inside the rotating platform device shell, and the output shaft of the second motor being connected to the middle part of the chuck body of the three-jaw chuck through the through hole.

2. The spherical gyrator part induction heating apparatus according to claim 1, characterized in that, The base comprises a base body and a mounting platform, the base body comprising four ground anchors fixed to the ground, the mounting platform being above the base body and connected with the concentric lifting platform.

3. The spherical gyrator part induction heating apparatus according to claim 1, characterized in that, The centering lifting platform comprises a first motor, a ball screw screw synchronous elevator, a centering lifting platform device coupling, a ball screw nut and a lifting platform, the first motor is connected with the ball screw screw synchronous elevator through the centering lifting platform device coupling, the ball screw screw synchronous elevator is arranged above the base, the ball screw nut at the top of the ball screw screw synchronous elevator is connected with the lifting platform, the lifting platform is connected with the inclination adjusting device above, and the first motor drives the lifting movement of the ball screw screw synchronous elevator through the centering lifting platform device coupling, so as to drive the lifting movement of the lifting platform.

4. The spherical gyrator part induction heating apparatus according to claim 1, characterized in that, The cross section of the rotating platform device connecting leg is in the shape of a Chinese character, and the rotating platform device shell is a lower opening cylindrical shell.

5. The spherical gyrator part induction heating apparatus according to claim 1, characterized in that, The induction coil adopts a ring-shaped single-turn copper pipe, and the three-jaw chuck body is made of alloy steel, and the inner side of the three-jaw chuck is provided with a ceramic insulating block.

6. A method of inductively heating a spheroidal part, implemented by means of the inductive heating device for a spheroidal part according to any one of the preceding claims 1-5, characterized in that, The method comprises the following steps: The spherical rotary part is divided into a spherical top region, a spherical middle region and a transition region to obtain a spherical rotary part to be processed; The spherical rotary part to be processed is vertically clamped in the three-jaw chuck, a first motor is started, the first motor drives the ball screw screw synchronous elevator through the centering lifting platform device coupling to adjust the height of the lifting platform, and the spherical rotary part to be processed is adjusted to a preset height; According to the specification parameters of the spherical rotary part to be processed, the distance between the spherical rotary part to be processed and the induction coil is adjusted; A stepping motor is started, the stepping motor drives the screw rod to rotate through the inclination adjusting device coupling, drives the travel block to move along the screw rod, the travel block pushes the inclination adjusting device support platform through the connecting rod, and the included angle between the spherical rotary part and the horizontal plane is adjusted to a preset angle; An angle sensor collects a heating angle, transmits the heating angle to a central control processor, the central control processor calls an angle-rotation speed matching database based on simulation optimization, matches the optimal rotation speed of each region, adjusts the rotation speed of a second motor based on the optimal rotation speed to drive the three-jaw chuck to rotate the spherical rotary part, and starts a high-frequency power supply to generate a high-frequency current, the high-frequency current passes through the induction coil, the induction coil cooperates with the magnetic conductor to generate a magnetic field, and the spherical top region, the spherical middle region and the transition region in the spherical rotary part are sequentially heated. The method further comprises:

7. The spherical gyroidal part induction heating method according to claim 6, characterized in that, During the heating process, the temperature of the spherical top region, the spherical middle region and the transition region is monitored in real time through an infrared monitoring and scanning system to ensure that the target temperature is reached and the uniformity parameters of the temperatures of the regions are controlled; An overlapping heating zone is arranged when adjacent regions are switched, and the super-temperature alarm system automatically cuts off power protection when the temperature exceeds the pre-warning temperature. The angle-rotation speed matching database is established by the following method:

8. The spherical gyroidal part induction heating method according to claim 6, characterized by, Step 1, modeling of the spherical rotary part is performed on an electromagnetic-thermal coupling simulation platform, and the reference rotation speed, the adjustment rotation speed and the maximum iteration number of the model are set. ​ Step 2, the heating angle is divided according to the preset interval, and the partition simulation is performed on the simulation platform according to the division result; Step 3, according to the simulation results, extracting temperature field data, based on the temperature field data, the uniformity standard test, the uniformity standard test according to the temperature uniformity index test, if the temperature uniformity index is greater than 15%, the temperature uniformity is judged to be unqualified, the high temperature area position is identified by thermal imaging analysis, the high temperature area is located at the bottom of the heating area, and the V new =V prev +ΔV speed-up strategy is adopted, the high temperature area is located at the top of the heating area, and the V new =V prev -ΔV speed-down strategy is adopted, wherein V new is the updated speed, V prev is the speed before updating, and ΔV is the adjusted speed. After adjustment, a new simulation verification is started. After each adjustment, the speed parameter is updated and the iteration counter is incremented. When the number of iterations reaches the maximum number of iterations, the iteration counter is reset and the adjusted speed is halved. The optimal speed parameters corresponding to all intervals are completed, and an initial angle-speed matching database is constructed. If the temperature uniformity index is less than or equal to 15%, it is judged that the temperature uniformity meets the standard, the speed result in the simulation result is recorded, and an initial angle-speed matching database is constructed based on the speed result. The calculation formula of the temperature uniformity index is: a = (T max - T min ) / T avg wherein a is a temperature uniformity index, T max is the maximum temperature within the simulation region, T min is the minimum temperature within the simulation region, T avg is the average temperature within the simulation region; Step 4, the initial angle-speed matching database is verified on the experimental platform, if the error is less than or equal to 5%, the initial angle-speed matching database is confirmed as the angle-speed matching database; if the error is greater than 5%, the model needs to be corrected, and steps 2 to 4 are repeated until the error is less than or equal to 5%.

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