Gear composite forming device and method based on waste heat utilization

Abstract

This invention discloses a gear composite forming apparatus and method based on waste heat utilization. The invention relates to the field of heat treatment technology and includes a frame. A cooling box is welded to the top of the frame, and an internal threaded ring is welded to the opening of the cooling box. A driving mechanism is provided in the inner cavity of the frame to drive the gear to rotate. A heating mechanism is threadedly connected to the inner cavity of the internal threaded ring to generate an induced current on the gear surface. The heating mechanism includes an external threaded ring threadedly connected to the inner cavity of the internal threaded ring. A discharge pipe is welded to the inner wall of the external threaded ring, and a vent ring is welded to the top of the discharge pipe. A casing is welded to the outer surface of the vent ring. By setting up the cooling box, coolant required for cooling the high-temperature gear can be stored, achieving the effect of fully utilizing waste heat while heat treating the gear.

Description

Technical Field

[0001] This invention relates to the field of heat treatment technology, specifically to a gear composite forming apparatus and method based on waste heat utilization. Background Technology

[0002] Gear heat treatment is a key process in mechanical manufacturing, aiming to significantly improve the mechanical properties of gears by controlling the heating, holding, and cooling processes. Its core objective is to obtain high tooth surface hardness to enhance wear resistance, while ensuring good strength and toughness in the core, thus enabling it to withstand complex alternating loads and impacts. Common processes include normalizing, quenching and tempering, carburizing and quenching, induction hardening, and nitriding. Normalizing refines the grain size and improves the microstructure to prepare for subsequent processing; quenching and tempering (quenching + high-temperature tempering) gives gears excellent comprehensive mechanical properties; carburizing and quenching are widely used in low-carbon alloy steel gears, forming a high-carbon wear-resistant layer on the surface while maintaining the strength and toughness of the core; induction hardening can achieve localized selective hardening of the tooth surface with minimal deformation; and nitriding can impart extremely high surface hardness, wear resistance, and fatigue resistance to gears at relatively low temperatures.

[0003] If the residual heat after forging is not fully utilized for preheating during gear heat treatment, it will directly lead to a significant increase in production energy consumption. The cold gear blank must be reheated from room temperature, which requires the heat treatment equipment to invest additional energy and time to slowly heat the workpiece to the target preheating temperature, increasing energy consumption and production costs. This independent preheating process also prolongs the overall production cycle and reduces equipment utilization and production efficiency. Summary of the Invention

[0004] To achieve the above objectives, the present invention provides the following technical solution: a gear composite forming device based on waste heat utilization, comprising a frame, a cooling box welded to the top of the frame, an internal threaded ring welded to the opening of the cooling box, a driving mechanism disposed within the inner cavity of the frame for driving gear rotation, a heating mechanism threadedly connected to the inner cavity of the internal threaded ring for generating induced current on the gear surface, the heating mechanism comprising an external threaded ring threadedly connected to the inner cavity of the internal threaded ring, a discharge pipe welded to the inner wall of the external threaded ring, a vent ring welded to the top of the discharge pipe, and the outer surface of the vent ring... The gear is welded with a protective casing, and a cooling tank is included to store the coolant needed to cool the high-temperature gears. A drive mechanism provides a rotational force to the gears during heat treatment, ensuring uniform heating of the gear's outer surface. Simultaneously, it ensures that the coolant contacts the gear requiring rapid cooling evenly when needed. An external threaded ring connects to an internal threaded ring, linking the heating mechanism to the cooling tank and facilitating subsequent cleaning. A discharge pipe guides the high-temperature gears, ensuring smooth passage. The waste gas is discharged into the inner cavity of the cooling box through the discharge pipe. A vent ring allows the hot air generated during gear heat treatment to enter the inner cavity of the packing box. The packing box also helps to channel the residual heat generated during gear heat treatment, thus preheating the gears. A material placement mechanism is located directly above the packing box. This mechanism holds the gears to be heat-treated. The material placement mechanism includes a top frame located directly above the packing box. A hydraulic cylinder is fixedly connected to the inner wall of the top frame. A moving rod is located at the movable end of the hydraulic cylinder, and a movable tube is located at the bottom end of the moving rod. A sliding sleeve is fitted onto the outer surface of the movable tube. The sliding tube has a blocking mechanism on its outer surface. By setting a feeding mechanism, multiple gears that need to be heat-treated can be clamped and positioned during operation. Then, when the gears need to be heat-treated, it cooperates with the drive mechanism to make the gears rotate stably inside the heating mechanism, so as to achieve the effect of uniform heating of the gears. Then, the high-temperature gears are controlled to slide into the inner cavity of the cooling box. By setting a hydraulic cylinder, the moving rod can be controlled to drive the moving tube to move vertically up and down in the inner cavity of the sliding tube during operation. By setting a blocking mechanism, the gears can be blocked or fall down under the control of the hydraulic cylinder and the up and down movement of the moving tube.

[0005] Preferably, the upper surface of the cooling box has an inlet valve, the lower surface of the cooling box has a drain valve, the drive mechanism includes a stepper motor, the stepper motor is fixedly connected to the bottom of the inner wall of the frame, the output end of the stepper motor is mounted with a rotating rod through a coupling, the top end of the rotating rod is welded with a rotating column, the rotating column penetrates the lower surface of the cooling box, the top end of the rotating column has a hexagonal cross-section, the outer surface of the rotating column is fixedly connected with a first rolling bearing, the outer ring of the first rolling bearing is fixedly connected to the inner wall of the cooling box, and an agitator plate is welded to one side of the outer surface of the rotating column located in the inner cavity of the cooling box.

[0006] Preferably, the discharge pipe has a gear-shaped cross-section, and a connecting cylinder is welded to the top of the inner wall of the vent ring. The connecting cylinder has a gear-shaped cross-section, and a positioning ring is welded to the upper surface of the connecting cylinder. The number of positioning rings is several, and the several positioning rings are evenly distributed.

[0007] Preferably, a connecting plate is riveted to the outer surface of the package box, and a transformer is riveted to the side of the connecting plate away from the package box. A connecting wire is provided at the output end of the transformer, and the connecting wire passes through the vent ring. An induction coil is fixedly connected to one end of the connecting wire located in the inner cavity of the vent ring.

[0008] Preferably, a locking ring is welded to the top of the package box, and a plurality of positioning holes are provided on the upper surface of the locking ring. A locking block is welded to the side of the lower surface of the top frame, and the number of the locking blocks is plurality of them, each of which is aligned with a plurality of positioning holes provided on the upper surface of the locking ring. A vent plate is welded to the lower surface of the top frame, and a positioning post is riveted to the lower surface of the vent plate. The number of the positioning posts is plurality of them, and the positioning posts are evenly distributed. The bottom end of the positioning post is piston-connected to the inner cavity of the positioning ring.

[0009] Preferably, a limiting post is welded to the bottom end of the movable rod, a rotating sleeve is sleeved on the outer surface of the limiting post, a second rolling bearing is fixedly connected to the outer surface of the limiting post, the outer ring of the second rolling bearing is fixedly connected to the inner wall of the rotating sleeve, and the rotating sleeve is welded to the upper surface of the movable tube.

[0010] Preferably, a sliding block is welded to the outer surface of the movable tube, a toothed plate is welded to the end of the sliding block away from the movable tube, a track groove is passed through the outer surface of the sliding tube, the sliding block is slidably connected to the track groove, a hexagonal sleeve is welded to the bottom end of the sliding tube, the hexagonal sleeve is fitted onto the top of the rotating column, and a barrier plate is welded to the bottom of the outer surface of the sliding tube.

[0011] Preferably, there are two barrier mechanisms, and the two barrier mechanisms are respectively disposed in the inner cavity of the package box and the inner cavity of the vent ring. Each barrier mechanism includes a fixing ring, a limit rod welded to the inner wall of the fixing ring, a third rolling bearing fixedly connected to the outer surface of the limit rod, and a rotating tube fixedly connected to the outer surface of the third rolling bearing.

[0012] Preferably, a half-circle gear is welded to the side of the rotating tube near the toothed plate, the half-circle gear meshes with the toothed plate, a connecting frame is welded to the side of the rotating tube away from the half-circle gear, a sector plate is riveted to the end of the connecting frame away from the rotating tube, and a blocking block is riveted to the upper surface of the sector plate.

[0013] A gear composite forming method based on waste heat utilization includes the following steps:

[0014] Step 1: Inject an appropriate amount of coolant into the cooling box, place the gear to be heat-treated on the outer surface of the sliding tube of the feeding mechanism, start the hydraulic cylinder to retract its movable end, and drive the moving rod to raise the movable tube to the highest point, thereby blocking the gear that needs to be heated by the blocking mechanism.

[0015] Step 2: The drive mechanism is started, which drives the sliding tube and gear to rotate at high speed and uniformly. The heating mechanism is connected to the power supply and powered on. The heating mechanism generates an alternating magnetic field, which generates eddy currents on the surface of the rotating gear for induction heating until the target austenitizing temperature is reached.

[0016] Step 3: After heating is complete, the moving end of the hydraulic cylinder retracts rapidly, pulling the moving tube upwards quickly. The upward movement causes the blocking mechanism to move in the opposite direction, driving the blocking mechanism to rotate 180° back to the "closed" state, so that the high-temperature gear at the top is no longer blocked. Then, driven by the gravity of the high-temperature gear, it quickly descends and is immersed in the coolant in the cooling box for quenching and cooling. The drive mechanism continues to work and stirs the coolant to make its temperature uniform and enhance the cooling effect on the gear, ensuring the quenching quality.

[0017] Step 4: After quenching, the drive mechanism stops rotating and the blocking mechanism is opened again, so that the preheated gears inside the package box fall back onto the blocking mechanism below. Repeat steps 2 to 3 above to achieve continuous production. After all gears have been heat-treated, the material placement mechanism is removed, and the gears can be recycled.

[0018] This invention provides a gear composite forming apparatus and method based on waste heat utilization. It has the following beneficial effects:

[0019] I. The gear composite forming device and method based on waste heat utilization, by setting a drive mechanism, can provide a rotational force to the gear during the gear heat treatment process, so that the outer surface of the gear can be uniformly heated by the heating mechanism, and at the same time, when the high-temperature gear needs to be cooled, the coolant can be uniformly contacted with the gear that needs to be cooled quickly.

[0020] II. The gear composite forming device and method based on waste heat utilization, by setting up a material feeding mechanism, can clamp and position multiple gears that need to be heat treated during operation. Then, when the gears need to be heat treated, it cooperates with the drive mechanism to make the gears rotate stably inside the heating mechanism, so as to achieve the effect of uniform heating of the gears. After that, the high-temperature gears are controlled to slide into the inner cavity of the cooling box.

[0021] Third, the gear composite forming device and method based on waste heat utilization can control the magnitude of the current flowing into the induction coil through the connecting wire by setting a transformer, thereby generating eddy currents on the gear through the induction coil, and generating eddy currents on the gear surface for induction heating until the target austenitizing temperature is reached.

[0022] IV. The gear composite forming device and method based on waste heat utilization, by setting a sliding block and a toothed plate, can make the sliding block move up and down in the track groove on the outer surface of the sliding tube when the movable tube moves up and down, thereby making the toothed plate move up and down to open or close the blocking mechanism. By setting a hexagonal sleeve, the hexagonal sleeve can drive the sliding tube to rotate when the rotating column rotates. By setting a blocking plate, the gear can be prevented from disengaging from the sliding tube.

[0023] V. The gear composite forming device and method based on waste heat utilization, by setting two blocking mechanisms, the blocking mechanism at the bottom can block the gear in the inner cavity of the vent ring, and the blocking mechanism at the top can block the preheated gear in the inner cavity of the packaging box. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the external structure of the gear composite forming device based on waste heat utilization according to the present invention.

[0025] Figure 2 This is a side view of the gear composite forming device based on waste heat utilization according to the present invention.

[0026] Figure 3 This is a schematic cross-sectional view of the gear composite forming device based on waste heat utilization according to the present invention.

[0027] Figure 4 This is a schematic diagram of the drive mechanism structure of the present invention;

[0028] Figure 5This is a schematic diagram of the heating mechanism structure of the present invention;

[0029] Figure 6 This is a partial structural diagram of the heating mechanism of the present invention;

[0030] Figure 7 This is a schematic diagram of the material feeding mechanism of the present invention;

[0031] Figure 8 This is a side view of the material feeding mechanism structure of the present invention;

[0032] Figure 9 This is a schematic cross-sectional view of the material feeding mechanism of the present invention;

[0033] Figure 10 This is a partial structural diagram of the material feeding mechanism of the present invention;

[0034] Figure 11 This is a schematic diagram of the barrier mechanism of the present invention.

[0035] In the diagram: 1. Frame; 2. Cooling box; 3. Internal threaded ring; 4. Drive mechanism; 5. Heating mechanism; 6. Packing box; 7. Locking ring; 8. Material feeding mechanism; 9. Inlet valve; 10. Drain valve; 41. Stepper motor; 42. Rotating rod; 43. Rotating column; 44. Stirring plate; 45. First rolling bearing; 51. External threaded ring; 52. Discharge pipe; 53. Vent ring; 54. Connecting cylinder; 55. Positioning ring; 56. Connecting plate; 57. Transformer; 58. Connecting wire; 59. Induction coil; 81. Top frame; 82. Locking block 83. Ventilation plate; 84. Hydraulic cylinder; 85. Positioning post; 86. Moving rod; 87. Movable tube; 88. Sliding tube; 89. Barrier mechanism; 810. Hexagonal sleeve; 811. Barrier disc; 812. Rotating sleeve; 813. Second rolling bearing; 814. Limiting post; 815. Sliding block; 816. Toothed plate; 817. Track groove; 891. Fixed ring; 892. Limiting rod; 893. Third rolling bearing; 894. Rotating tube; 895. Half-circle gear; 896. Connecting frame; 897. Sector plate; 898. Barrier block. Detailed Implementation

[0036] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments. The embodiments of the present invention are given for illustrative and descriptive purposes only, and are not intended to be exhaustive or to limit the invention to the forms disclosed. Many modifications and variations will be apparent to those skilled in the art. The embodiments were chosen and described to better illustrate the principles and practical application of the invention, and to enable those skilled in the art to understand the invention and design various embodiments with various modifications suitable for a particular purpose.

[0037] like Figures 1-11As shown, the present invention provides a technical solution: a gear composite forming device based on waste heat utilization, including a frame 1, a cooling box 2 welded to the top of the frame 1, an internal threaded ring 3 welded to the opening of the cooling box 2, a drive mechanism 4 provided in the inner cavity of the frame 1, the drive mechanism 4 being used to drive the gear to rotate, a heating mechanism 5 threadedly connected to the inner cavity of the internal threaded ring 3, the heating mechanism 5 being used to generate an induced current on the gear surface, the heating mechanism 5 including an external threaded ring 51, the external threaded ring 51 being threadedly connected to the inner cavity of the internal threaded ring 3, a discharge pipe 52 welded to the inner wall of the external threaded ring 51, a vent ring 53 welded to the top of the discharge pipe 52, and a wrapping box 6 welded to the outer surface of the vent ring 53. A cooling tank 2 is provided to store the coolant needed for cooling the high-temperature gears. A drive mechanism 4 provides a rotational force to the gears during heat treatment, ensuring uniform heating of the gear's outer surface by the heating mechanism 5. Simultaneously, it ensures that the coolant contacts the gear requiring rapid cooling evenly when needed. An external threaded ring 51 connects to an internal threaded ring 3, linking the heating mechanism 5 to the cooling tank 2 and facilitating subsequent cleaning of the cooling tank 2. A discharge pipe 52 guides the high-temperature gears, allowing them to smoothly drain into the cooling tank 2. Inside the cavity, a vent ring 53 is provided to allow the hot air generated during gear heat treatment to enter the inner cavity of the packaging box 6. The packaging box 6 also allows for the diversion of residual heat generated during gear heat treatment, thus enabling the gears to be preheated. A material placement mechanism 8 is located directly above the packaging box 6. This mechanism is used to place the gears requiring heat treatment. The material placement mechanism 8 includes a top frame 81, located directly above the packaging box 6. A hydraulic cylinder 84 is fixedly connected to the inner wall of the top frame 81. A moving rod 86 is provided at the movable end of the hydraulic cylinder 84, and a movable tube 87 is provided at the bottom end of the moving rod 86. A sliding tube 88 is fitted onto the outer surface of the movable tube 87. The outer surface of 88 is provided with a blocking mechanism 89. By setting up a feeding mechanism 8, multiple gears that need to be heat-treated can be clamped and positioned during operation. Then, when the gears need to be heat-treated, it cooperates with the drive mechanism 4 to make the gears rotate stably inside the heating mechanism 5, so as to achieve the effect of uniform heating of the gears. Then, the high-temperature gears are controlled to slide into the inner cavity of the cooling box 2. By setting up a hydraulic cylinder 84, during operation, the moving rod 86 can be controlled to drive the movable tube 87 to move vertically up and down in the inner cavity of the sliding tube 88. By setting up a blocking mechanism 89, the gears can be blocked or fall down under the control of the hydraulic cylinder 84 and the up and down movement of the movable tube 87.

[0038] A liquid inlet valve 9 penetrates the upper surface of the cooling tank 2, and a liquid drain valve 10 penetrates the lower surface of the cooling tank 2. The drive mechanism 4 includes a stepper motor 41, which is fixedly connected to the bottom of the inner wall of the frame 1. A rotating rod 42 is mounted on the output end of the stepper motor 41 via a coupling. A rotating column 43 is welded to the top of the rotating rod 42, penetrating the lower surface of the cooling tank 2. The top of the rotating column 43 has a hexagonal cross-section, and a first rolling bearing 45 is fixedly connected to the outer surface of the rotating column 43. The outer ring of the first rolling bearing 45 is fixedly connected to the inner wall of the cooling tank 2. A stirring plate 44 is welded to the outer surface of the moving column 43 on one side of the inner cavity of the cooling tank 2. By setting the drain valve 10 and the inlet valve 9, the coolant can be easily poured into or discharged from the cooling tank 2. By setting the stepper motor 41, the rotating rod 42 can be rotated after the power is connected and the switch is turned on, thereby causing the rotating column 43 to rotate. By setting the first rolling bearing 45, the rotating column 43 can be rotated stably. By setting the stirring plate 44, the stirring plate 44 can agitate the coolant in the inner cavity of the cooling tank 2 when the rotating column 43 rotates.

[0039] The discharge pipe 52 has a gear-shaped cross-section. A connecting cylinder 54 is welded to the top of the inner wall of the vent ring 53. The connecting cylinder 54 also has a gear-shaped cross-section. A positioning ring 55 is welded to the upper surface of the connecting cylinder 54. There are several positioning rings 55, which are evenly distributed. By setting the cross-section of the discharge pipe 52 to be gear-shaped, the high-temperature gear can slide stably into the inner cavity of the cooling box 2. By setting the positioning rings 55, the material placement mechanism 8 can be positioned. The outer surface of the wrapping box 6 is riveted. A connecting plate 56 is attached, and a transformer 57 is riveted to the side of the connecting plate 56 away from the package box 6. A connecting wire 58 is provided at the output end of the transformer 57. The connecting wire 58 passes through the vent ring 53. An induction coil 59 is fixedly connected to one end of the connecting wire 58 located in the inner cavity of the vent ring 53. By setting the transformer 57, the magnitude of the current flowing into the induction coil 59 from the connecting wire 58 can be controlled, thereby controlling the magnitude of the eddy current generated by the induction coil 59 on the gear. The eddy current generated on the surface of the gear is used for induction heating until the target austenitizing temperature is reached.

[0040] A locking ring 7 is welded to the top of the package box 6. The upper surface of the locking ring 7 has several positioning holes. A locking block 82 is welded to the side of the lower surface of the top frame 81. Several locking blocks 82 are aligned with the positioning holes on the upper surface of the locking ring 7. A vent plate 83 is welded to the lower surface of the top frame 81. Positioning posts 85 are riveted to the lower surface of the vent plate 83. Several positioning posts 85 are evenly distributed. The bottom piston of each positioning post 85 is connected to the inner cavity of the positioning ring 55. By setting the locking ring 7 and providing several positioning holes on its upper surface, the top frame 81 can be aligned with the positioning ring 55 during installation. The locking block 82 on the lower surface of the top frame 81 cooperates with the top frame 81 to position the top frame 81 at the opening of the parcel box 6. By setting a vent plate 83, excess heat in the inner cavity of the parcel box 6 can be discharged through the holes in the vent plate 83 and the top frame 81. By setting several positioning posts 85 on the lower surface of the vent plate 83, the gears placed at the material feeding mechanism 8 can be arranged and positioned to prevent leakage and blockage caused by inconsistent gear and rack positions. At the same time, it can prevent the material feeding mechanism 8 from shifting during installation. The bottom end of the moving rod 86 is welded with a limiting post 814. A rotating sleeve 812 is sleeved on the outer surface of the limiting post 814. A second rolling bearing 813 is fixedly connected to the outer surface of the limiting post 814. The outer ring of the second rolling bearing 813 is fixedly connected to the inner wall of the rotating sleeve 812. The rotating sleeve 812 is welded to the upper surface of the movable tube 87. By setting the limiting post 814 and the second rolling bearing 813, the rotating sleeve 812 can be limited, allowing the rotating sleeve 812 to rotate stably on the outer surface of the limiting post 814. This ensures that when the moving rod 86 moves the movable tube 87 up and down, the moving rod 86 does not obstruct the rotation of the movable tube 87. A sliding block 815 is welded to the outer surface of the movable tube 87. A toothed plate 816 is welded to the end of the sliding block 815 away from the movable tube 87. A track groove 817 penetrates the outer surface of the sliding tube 87. The sliding block 815 is slidably connected to... At the track groove 817, a hexagonal sleeve 810 is welded to the bottom end of the sliding tube 88. The hexagonal sleeve 810 is fitted onto the top of the rotating column 43. A baffle plate 811 is welded to the bottom of the outer surface of the sliding tube 88. By setting a sliding block 815 and a toothed plate 816, when the movable tube 87 moves up and down, the sliding block 815 can move up and down at the track groove 817 on the outer surface of the sliding tube 88, thereby causing the toothed plate 816 to move up and down, so that the baffle mechanism 89 can be opened or closed. By setting a hexagonal sleeve 810, when the rotating column 43 rotates, the hexagonal sleeve 810 can drive the sliding tube 88 to rotate. By setting a baffle plate 811, the gear can be prevented from disengaging from the sliding tube 88.

[0041] There are two blocking mechanisms 89, which are respectively located in the inner cavity of the package box 6 and the inner cavity of the vent ring 53. Each blocking mechanism 89 includes a fixing ring 891, with a limit rod 892 welded to the inner wall of the fixing ring 891. A third rolling bearing 893 is fixedly connected to the outer surface of the limit rod 892, and a rotating tube 894 is fixedly connected to the outer surface of the third rolling bearing 893. By setting two blocking mechanisms 89, the bottom blocking mechanism 89 can block the gear in the inner cavity of the vent ring 53, while the top blocking mechanism 89 can block the preheated gear in the inner cavity of the package box 6. The limit rod 892 and the third rolling bearing 893 allow the rotating tube 894 to rotate stably. A half-circle gear 895 is welded to the side of the rotating tube 894 near the toothed plate 816. Gear 895 meshes with toothed plate 816. A connecting frame 896 is welded to the side of rotating tube 894 away from half-circle gear 895. A sector plate 897 is riveted to the end of connecting frame 896 away from rotating tube 894. A blocking block 898 is riveted to the upper surface of sector plate 897. By setting half-circle gear 895, when toothed plate 816 moves upward, half-circle gear 895 drives rotating tube 894 to rotate downward, thereby preventing sector plate 897 and blocking block 898 from contacting the lower surface of gear. This prevents high-temperature gear from being blocked by sector plate 897 and allows high-temperature gear to move downward. By setting blocking block 898, it can contact the hole of gear. When sliding tube 88 rotates, it drives gear to rotate. The blocking mechanism 89 above does not have blocking block 898 on the surface of sector plate 897.

[0042] A gear composite forming method based on waste heat utilization includes the following steps:

[0043] Step 1: Inject an appropriate amount of coolant, such as quenching oil, into the cooling box 2. Place the gear to be heat-treated on the outer surface of the sliding tube 88 of the material placement mechanism 8. Start the hydraulic cylinder 84 to retract its movable end and drive the moving rod 86. The movable tube 87 rises to the highest point, thereby blocking the gear that needs to be heated by the blocking mechanism 89.

[0044] Step 2: The drive mechanism 4 is started, which drives the sliding tube 88 and the gear to rotate at high speed and uniformly. The heating mechanism 5 is connected to the power supply and powered on. The heating mechanism 5 generates an alternating magnetic field, which generates eddy currents on the surface of the rotating gear for induction heating until the target austenitizing temperature, such as 850-900℃, is reached.

[0045] Step 3: After heating is completed, the movable end of the hydraulic cylinder 84 retracts rapidly, pulling the movable tube 87 upwards quickly. The upward movement causes the blocking mechanism 89 to move in the opposite direction, driving the blocking mechanism 89 to rotate 180° back to the "closed" state, so that the high-temperature gear located at the top is no longer blocked. Then, under the gravity drive of the high-temperature gear, it quickly descends and is immersed in the coolant in the cooling box 2 for quenching and cooling. The drive mechanism 4 continues to work and stirs the coolant to make its temperature uniform and enhance the cooling effect on the gear, ensuring the quenching quality and obtaining the martensitic structure.

[0046] Step 4: After quenching, the drive mechanism 4 stops rotating and the blocking mechanism 89 is opened again, so that the preheated gear inside the packaging box 6 falls back onto the blocking mechanism 89 located below. Repeat steps 2 to 3 above to achieve continuous production. After all gears have been heat-treated, the material placement mechanism 8 is removed, and the gears can be recycled.

[0047] Working principle: In use, an appropriate amount of coolant, such as quenching oil, is injected into the cooling tank 2 through the inlet valve 9. The gear to be heat-treated is placed on the outer surface of the sliding tube 88 of the feeding mechanism 8, and the feeding mechanism 8 is inserted into the inner cavity of the heating mechanism 5. The locking block 82 is inserted into the positioning ring 55, and the hexagonal sleeve 810 is placed on the outer surface of the rotating column 43. The hydraulic cylinder 84 is activated, causing its movable end to retract and driving the moving rod 86. The movable tube 87 rises to its highest point, thereby allowing the blocking mechanism 89 to block the gear to be heated. Gear blocking: After the device is installed and one gear is on the upper surface of the bottom blocking mechanism 89, the stepper motor 41 is connected to the power supply and its switch is turned on, so that the rotating column 43 drives the hexagonal sleeve 810 to drive the sliding tube 88 and the gear to rotate evenly. Then, the transformer 57 of the heating mechanism 5 is energized, and the induction coil 59 is powered through the connecting wire 58. The induction coil 59 generates an alternating magnetic field, which generates eddy currents on the surface of the rotating gear for induction heating until the target austenitizing temperature, such as 850-900℃, is reached. After heating, the movable end of the hydraulic cylinder 84 retracts rapidly, pulling the movable tube 87 upwards. This upward movement causes the blocking mechanism 89 to move in the opposite direction. As the movable tube 87 drives the toothed plate 816 upwards, the toothed plate 816 meshes with the half-circle gear 895, causing the rotating tube 894 to rotate on the outer surface of the limit rod 892. This ultimately drives the sector plate 897 to rotate 180° back to the "closed" state, freeing the high-temperature gear at the top from obstruction. Subsequently, under the gravity of the high-temperature gear, it rapidly descends and immerses itself in the coolant in the cooling box 2 for quenching. The drive mechanism 4 continues to work and agitates the coolant to ensure uniform temperature and enhance the cooling effect on the gear, guaranteeing the quenching quality and obtaining a martensitic structure. After quenching, the drive mechanism 4 stops rotating and the blocking mechanism 89 is reopened, allowing the preheated gear inside the packaging box 6 to fall back onto the lower blocking mechanism 89. This process is repeated to achieve continuous production. After all gears have been heat-treated, the material placement mechanism 8 is removed, allowing the gears to be recycled.

[0048] Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. All other embodiments obtained by those skilled in the art and related fields based on the embodiments of the present invention without inventive effort should fall within the scope of protection of the present invention. Structures, devices, and operating methods not specifically described and explained in the present invention, unless otherwise specified or limited, shall be implemented according to conventional means in the art.

Claims

1. A gear composite forming device based on waste heat utilization, comprising a frame (1), wherein a cooling box (2) is welded to the top of the frame (1), and an internal threaded ring (3) is welded to the opening of the cooling box (2), characterized in that: A drive mechanism (4) is provided in the inner cavity of the frame (1). The drive mechanism (4) is used to drive the gear to rotate. A heating mechanism (5) is threadedly connected to the inner cavity of the internal threaded ring (3). The heating mechanism (5) is used to generate an induced current on the surface of the gear. The heating mechanism (5) includes an external threaded ring (51), which is threadedly connected to the inner cavity of the internal threaded ring (3). A discharge pipe (52) is welded to the inner wall of the external threaded ring (51). A vent ring (53) is welded to the top of the discharge pipe (52). A packaging box (6) is welded to the outer surface of the vent ring (53). A material placement mechanism (8) is provided directly above the package box (6). The material placement mechanism (8) is used to place gears that need to be heat treated. The material placement mechanism (8) includes a top frame (81). The top frame (81) is located directly above the package box (6). A hydraulic cylinder (84) is fixedly connected to the inner wall of the top frame (81). A moving rod (86) is provided at the movable end of the hydraulic cylinder (84). A moving tube (87) is provided at the bottom end of the moving rod (86). A sliding tube (88) is sleeved on the outer surface of the moving tube (87). A blocking mechanism (89) is provided on the outer surface of the sliding tube (88). The number of the barrier mechanisms (89) is two, and the two barrier mechanisms (89) are respectively disposed in the inner cavity of the package box (6) and the inner cavity of the vent ring (53). The barrier mechanism (89) includes a fixing ring (891), and a limiting rod (892) is welded to the inner wall of the fixing ring (891). A third rolling bearing (893) is fixedly connected to the outer surface of the limiting rod (892), and a rotating bearing (893) is fixedly connected to the outer surface of the third rolling bearing (893). The rotating tube (894) has a half-circle gear (895) welded to the side of the rotating tube (894) near the toothed plate (816), the half-circle gear (895) meshing with the toothed plate (816), a connecting frame (896) welded to the side of the rotating tube (894) away from the half-circle gear (895), a sector plate (897) riveted to the end of the connecting frame (896) away from the rotating tube (894), and a blocking block (898) riveted to the upper surface of the sector plate (897). The upper surface of the cooling box (2) is penetrated by an inlet valve (9), and the lower surface of the cooling box (2) is penetrated by a drain valve (10). The drive mechanism (4) includes a stepper motor (41). The stepper motor (41) is fixedly connected to the bottom of the inner wall of the frame (1). The output end of the stepper motor (41) is equipped with a rotating rod (42) through a coupling. A rotating column (43) is welded to the top of the rotating rod (42). The rotating column (43) penetrates the lower surface of the cooling box (2). The top cross-section of the rotating column (43) is hexagonal. A first rolling bearing (45) is fixedly connected to the outer surface of the rotating column (43). The outer ring of the first rolling bearing (45) is fixedly connected to the inner wall of the cooling box (2). A stirring plate (44) is welded to one side of the inner cavity of the cooling box (2) on the outer surface of the rotating column (43). The discharge pipe (52) has a gear-shaped cross-section. A connecting cylinder (54) is welded to the top of the inner wall of the vent ring (53). The connecting cylinder (54) has a gear-shaped cross-section. A positioning ring (55) is welded to the upper surface of the connecting cylinder (54). There are several positioning rings (55), and they are evenly distributed. A connecting plate (56) is riveted to the outer surface of the package box (6). A transformer (57) is riveted to the side of the connecting plate (56) away from the package box (6). A connecting wire (58) is provided at the output end of the transformer (57). The connecting wire (58) passes through the vent ring (53). An induction coil (59) is fixedly connected to one end of the connecting wire (58) located in the inner cavity of the vent ring (53).

2. The gear composite forming device based on waste heat utilization according to claim 1, characterized in that: The top of the package box (6) is welded with a locking ring (7), and the upper surface of the locking ring (7) is provided with a number of positioning holes. The side of the lower surface of the top frame (81) is welded with a locking block (82), and there are several locking blocks (82), and the several locking blocks (82) are respectively aligned with the several positioning holes provided on the upper surface of the locking ring (7). The lower surface of the top frame (81) is welded with a vent plate (83), and the lower surface of the vent plate (83) is riveted with a positioning post (85), and there are several positioning posts (85), and the several positioning posts (85) are evenly distributed. The bottom piston of the positioning post (85) is connected to the inner cavity of the positioning ring (55).

3. The gear composite forming device based on waste heat utilization according to claim 2, characterized in that: The bottom end of the moving rod (86) is welded with a limiting post (814), and a rotating sleeve (812) is sleeved on the outer surface of the limiting post (814). A second rolling bearing (813) is fixedly connected to the outer surface of the limiting post (814), and the outer ring of the second rolling bearing (813) is fixedly connected to the inner wall of the rotating sleeve (812). The rotating sleeve (812) is welded to the upper surface of the movable tube (87).

4. The gear composite forming device based on waste heat utilization according to claim 3, characterized in that: A sliding block (815) is welded to the outer surface of the movable tube (87). A toothed plate (816) is welded to the end of the sliding block (815) away from the movable tube (87). A track groove (817) runs through the outer surface of the sliding tube (88). The sliding block (815) is slidably connected to the track groove (817). A hexagonal sleeve (810) is welded to the bottom end of the sliding tube (88). The hexagonal sleeve (810) is fitted onto the top of the rotating column (43). A barrier plate (811) is welded to the bottom of the outer surface of the sliding tube (88).

5. A gear composite forming apparatus based on waste heat utilization according to any one of claims 1-4 provides a gear composite forming method based on waste heat utilization, characterized in that, Includes the following steps: Step 1: Inject an appropriate amount of coolant into the cooling box (2), place the gear to be heat-treated on the outer surface of the sliding tube (88) of the material placement mechanism (8), start the hydraulic cylinder (84) to retract its movable end, and drive the moving rod (86) so that the movable tube (87) rises to the highest point, thereby blocking the gear that needs to be heated by the blocking mechanism (89). Step 2: The drive mechanism (4) is started, which drives the sliding tube (88) and gear to rotate at high speed and uniformly. The heating mechanism (5) is connected to the power supply and powered on. The heating mechanism (5) generates an alternating magnetic field, which generates eddy currents on the surface of the rotating gear for induction heating until the target austenitizing temperature is reached. Step 3: After heating is completed, the movable end of the hydraulic cylinder (84) retracts rapidly, pulling the movable tube (87) to rise rapidly. The rising action causes the blocking mechanism (89) to move in the opposite direction, driving the blocking mechanism (89) to rotate 180° back to the "closed" state, so that the high-temperature gear located at the top is no longer blocked. Then, under the gravity drive of the high-temperature gear, it quickly descends and is immersed in the coolant in the cooling box (2) for quenching and cooling. The drive mechanism (4) continues to work and stirs the coolant to make its temperature uniform and enhance the cooling effect on the gear, ensuring the quenching quality. Step 4: After quenching, the drive mechanism (4) stops rotating and the barrier mechanism (89) is opened again, so that the preheated gear inside the package box (6) falls back onto the barrier mechanism (89) located below. Repeat steps 2 to 3 above to achieve continuous production. After all gears have been heat-treated, the material placement mechanism (8) is removed and the gears can be recycled.

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