Gear quenching device for gearbox and quenching method

Abstract

The application relates to a gearbox gear quenching device and a quenching method, and relates to the technical field of gear quenching. The device comprises a machine body and a cooling box mounted on the machine body. The cooling box is hollow and is provided with an opening, can accommodate quenching liquid, and simultaneously comprises a quencher, a conductive part and an induction heating ring. One end of the conductive part is connected with the quencher, the other end extends to above the opening of the cooling box and is connected with the induction heating ring, the induction heating ring is outwardly convex in the circumferential direction to form a plurality of trapezoidal heating frames matched with the gear tooth shape. A lifting supporting mechanism is arranged in the cooling box and supports the gear and drives the gear to move up and down. The conductive part is provided with detachable insulating parts to cut off positive and negative currents. The connecting part is used for fixing the insulating parts and partially melts to provide a safety prompt when short-circuit abnormality occurs. The device uniformly heats the gear tooth surface through the trapezoidal heating frames, improves the gear hardness and wear resistance, simultaneously has electrical safety and structural stability, and thus realizes efficient and safe gear quenching treatment.

Description

Technical Field

[0001] This application relates to the field of gear quenching technology, and in particular to a gearbox gear quenching device and quenching method. Background Technology

[0002] Currently, in metal processing, quenching, as a key process, effectively improves the hardness, wear resistance, fatigue strength, and toughness of steel or alloys by heating them to a specific temperature and then rapidly cooling them after holding at that temperature, thus meeting the application requirements of various mechanical parts and tools. Especially in gear manufacturing, quenching is of great significance for improving gear hardness and wear resistance.

[0003] However, research has revealed that uneven heating often occurs during the quenching process of specific gears used in transmissions, such as trapezoidal gears. This results in uneven distribution of hardness and wear resistance, affecting overall performance and service life. This problem exposes the shortcomings of existing technologies in the quenching process of trapezoidal gears, namely, the difficulty in ensuring the uniformity of the heating and cooling process, thus failing to fully meet the stability and reliability requirements of transmission gears. Summary of the Invention

[0004] This application provides a gearbox gear quenching apparatus and quenching method to at least partially solve the above-mentioned technical problems.

[0005] To achieve the above objectives, according to a first aspect of this application, a gearbox gear quenching apparatus is provided, comprising: Organism; A cooling box is installed on the machine body, and the interior of the cooling box is hollow with an opening at the top. The quencher, conductive component, and induction heating ring are provided. The quencher is mounted on the machine body and located on one side of the cooling box. The first end of the conductive component is electrically connected to the quencher, and the second end of the conductive component extends horizontally above the opening of the cooling box. The induction heating ring is electrically connected to the second end of the conductive component. The induction heating ring has multiple trapezoidal heating frames circumferentially convex outward, and each trapezoidal heating frame is configured to be adapted to a trapezoidal tooth of a trapezoidal gear. A lifting support mechanism is installed inside the cooling box and located directly below the induction heating ring. The lifting support mechanism is configured to place the trapezoidal gear and drive the trapezoidal gear to move in the vertical direction to enter or exit the inner ring of the induction heating ring. An insulating component is detachably connected to the conductive component, and the insulating component is used to block the positive current and negative current on the conductive component. A connector, disposed on the conductive element, is configured to fix an insulating element to the conductive element and to partially melt when a short circuit occurs in the conductive element, wherein the insulating element is an alumina ceramic plate; The connector includes a low-melting-point polymer cable tie and an insulating wire. The low-melting-point polymer cable tie is circumferentially and tightly sleeved on the outer surface of the conductive component and the alumina ceramic plate. The insulating wire is tightly wrapped around the outer surface of the low-melting-point polymer cable tie and is used to secure the alumina ceramic plate within the strip gap.

[0006] Optionally, the conductive element includes a positive electrode rod and a negative electrode rod, the positive electrode rod and the negative electrode rod are parallel and a strip gap is reserved between them, and the insulating element is installed in the strip gap; One of the multiple trapezoidal heating frames is a trapezoidal conductive frame. The first end of the positive electrode rod is electrically connected to the positive electrode of the quencher, and the second end is connected to the trapezoidal conductive frame. The first end of the negative electrode rod is electrically connected to the negative electrode of the quencher, and the second end is connected to the trapezoidal conductive frame.

[0007] Optionally, the trapezoidal conductive frame includes a positive electrode sub-frame and a negative electrode sub-frame, with a conductive gap reserved between the positive electrode sub-frame and the negative electrode sub-frame. The conductive gap communicates with the strip gap, and the insulating member is configured to extend into the trapezoidal conductive frame via the conductive gap.

[0008] Optionally, both the positive and negative electrode frames have arc-shaped protrusions on their inner frame walls near the conductive gap. Along the length of the strip gap, the longest straight-line distance between the arc-shaped protrusion and the end wall of the trapezoidal gear inside the trapezoidal conductive frame is configured as a, and the shortest straight-line distance between the end of the insulating member and the end wall of the trapezoidal gear inside the trapezoidal conductive frame is configured as b, where a < b.

[0009] Optionally, the length of the alumina ceramic plate is greater than the sum of the lengths of the strip gap and the conductive notch, the thickness of the alumina ceramic plate is less than the lateral width of the strip gap, and the width of the alumina ceramic plate is greater than the vertical width of the strip gap. The alumina ceramic plate is configured such that, when embedded within the strip gap, both its upper and lower ends are exposed outside the strip gap.

[0010] Optionally, the low-melting-point polymer cable tie, the conductive element, and the alumina ceramic plate form four triangular isolation cavities, which are used to separate the low-melting-point polymer cable tie from the strip gap.

[0011] Optionally, the low-melting-point polymer cable tie is a polyethylene cable tie or a polypropylene cable tie.

[0012] Optionally, the lifting support mechanism includes a cylinder, a mounting base, and a positioning column. The cylinder is mounted on the inner bottom wall of the cooling box and the piston rod of the cylinder extends vertically. The mounting base is located at the top of the piston rod of the cylinder, and the positioning column is located at the center of the upper surface of the mounting base and is configured to engage with the inner ring of the trapezoidal gear.

[0013] According to a second aspect of this application, a quenching method for gearbox gears is provided, implemented based on the gearbox gear quenching apparatus described in the first aspect, comprising the following steps: Pour the cooling quenching fluid into the cooling tank; Turn on the quencher to preheat the inner ring of the induction heating ring; Place the trapezoidal gear to be quenched onto the lifting support mechanism and adjust the position of the trapezoidal gear so that each trapezoidal tooth of the trapezoidal gear is directly opposite a trapezoidal heating frame. Start the lifting support mechanism to vertically move the trapezoidal gear to be quenched to the inner ring of the induction heating ring, and each trapezoidal tooth of the trapezoidal gear enters a trapezoidal heating frame for heating; Reactivate the lifting support mechanism to drive the heated trapezoidal gear vertically downwards into the cooling quenching liquid below the surface, completing the quenching process.

[0014] In summary, this application includes at least one of the following beneficial technical effects: 1. By setting up a cooling tank, quencher, conductive components, induction heating ring, lifting support mechanism, and insulating fixing structure, a complete process chain from heating to cooling is formed. The cooling tank ensures rapid cooling of the quenching liquid, and the induction heating ring, in conjunction with the gear tooth profile, achieves uniform heating, improving the consistency of hardness on the tooth surface and root. The lifting support mechanism ensures stable switching of the gear between heating and cooling, preventing misalignment. The insulating components and connecting parts not only isolate current and prevent short circuits, but also provide an indication through melting in case of abnormalities, thus balancing gear performance and operational safety. 2. Polyethylene or polypropylene cable ties melt rapidly during short-circuit overheating, preventing open flames and providing an abnormality warning. Residue enters the cooling box, reducing secondary risks. Simultaneously, insulating wires maintain the positioning of insulating components, and their high insulation and heat resistance ensure reliable fixation even under thermal shock. This ensures stable fastening during normal operation and provides visual warnings in abnormal situations, balancing operational safety and equipment reliability. 3. The arc-shaped protrusions are arranged along the length of the strip gap. Compared with the straight inner frame wall, the arc-shaped protrusions provide a larger heating surface area, allowing the trapezoidal gear end face covered by the arc-shaped protrusions to obtain more uniform heat transfer. The straight-line distance 'a' between the arc-shaped protrusions and the trapezoidal gear end wall is less than the straight-line distance 'b' between the end of the insulating component and the end wall of the trapezoidal gear. Therefore, the arc-shaped protrusions form a closer heating surface near the end face of the trapezoidal gear teeth, which helps to compensate for the reduced heat transfer caused by the insulating component occupying part of the inner wall space after extending into the trapezoidal conductive frame, thereby improving the heating uniformity of the trapezoidal gear to a certain extent. 4. The presence of the triangular isolation cavity helps to separate the low-melting-point polymer cable tie from the strip gap, preventing the cable tie from melting under normal operating conditions due to the normal heat generated by the current flowing through the strip gap. The spatial arrangement and geometry of the triangular isolation cavity establish a clear correlation between the thermal melting behavior of the low-melting-point polymer cable tie and abnormal device conditions. When a short circuit occurs in the conductive component or the entire heating circuit, the temperature of the conductive component rises sharply. The heat is conducted through contact to the low-melting-point polymer cable tie, which is in close contact with its outer surface. This causes the cable tie to partially melt under high temperature, thus providing an observable indicator to the operator that an abnormality has occurred and that power should be cut off immediately. The triangular isolation cavity provides a certain degree of thermal insulation protection for the low-melting-point polymer cable tie, preventing it from being affected by the heat generated by the normal current inside the strip gap. This avoids misjudging equipment failures. Furthermore, when a real malfunction occurs, the thermal melting behavior of the low-melting-point polymer cable tie can provide a relatively intuitive indication to the operator for intervention. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] To gain a more complete understanding of this application and its beneficial effects, the following description will be provided in conjunction with the accompanying drawings, wherein the same reference numerals in the following description denote the same parts.

[0017] Figure 1 This is a schematic diagram of the overall structure of the gearbox gear quenching device provided in the embodiments of this application; Figure 2 This is a top view of the gearbox gear quenching device provided in the embodiments of this application; Figure 3 This is a schematic diagram illustrating the connection relationship between the conductive component and the induction heating ring in the embodiments of this application. Figure 1 ; Figure 4This is a schematic diagram illustrating the connection relationship between the conductive component and the induction heating ring in the embodiments of this application. Figure 2 ; Figure 5 This is a partial cross-sectional view in the embodiments of this application used to show the triangular isolation cavity formed by the low-melting-point polymer cable tie, conductive component and alumina ceramic plate; Figure 6 This is a partial cross-sectional view of the gearbox gear quenching device provided in the application implementation.

[0018] Explanation of reference numerals in the attached figures: 1. Organism; 2. Cooling box; 3. Quenching equipment; 4. Conductive component; 41. Positive electrode conductor; 42. Negative electrode conductor; 43. Strip gap; 5. Induction heating ring; 51. Trapezoidal heating frame; 511. Trapezoidal conductive frame; 5111. Positive electrode frame; 5112. Negative electrode frame; 5113. Conductive notch; 6. Lifting support mechanism; 61. Cylinder; 62. Mounting base; 63. Positioning column; 7. Arc-shaped protrusion; 8. Insulating components; 81. Alumina ceramic plate; 9. Connectors; 91. Low-melting-point polymer cable ties; 92. Insulating cable ties; 10. Triangular isolation cavity. Detailed Implementation

[0019] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the protection scope of this application.

[0020] Firstly, this application provides a gearbox gear quenching apparatus; please refer to [link to relevant documentation]. Figure 1 and Figure 2 The gearbox gear quenching device includes a body 1, a cooling box 2, a quencher 3, a conductive component 4, an induction heating ring 5, a lifting support mechanism 6, an insulating component 8, and a connecting component 9. The cooling box 2 is installed on the body 1, and the interior of the cooling box 2 is a cavity with an opening at the top, allowing the liquid quenching medium to be poured into it and providing immersion space for quenching the trapezoidal gears.

[0021] For example, the quencher 3 is mounted on the body 1 and located on one side of the cooling box 2, and is able to provide initial preheating energy for the induction heating ring 5 so that the inner ring of the induction heating ring 5 reaches a suitable temperature before the trapezoidal gear enters.

[0022] For example, the first end of the conductive element 4 is electrically connected to the quencher 3, and the second end of the conductive element 4 extends horizontally above the opening of the cooling box 2, connecting to the induction heating ring 5, providing a path for current conduction and supporting the induction heating ring 5 to maintain a stable position. The induction heating ring 5 convexes outward in a circumferential direction to form multiple trapezoidal heating frames 51. Each trapezoidal heating frame 51 can cooperate with the trapezoidal teeth of the trapezoidal gear, so that each trapezoidal tooth can receive relatively uniform heat when the trapezoidal gear is heated, thereby improving the hardness and wear resistance distribution of the gear surface and tooth root to a certain extent.

[0023] It is understandable that the geometry and size of the trapezoidal heating frame 51 can be adjusted according to the trapezoidal gear tooth profile design, so that the heating contact surface matches the tooth surface and reduces the situation of insufficient or excessive heating of some tooth surfaces, thereby providing a beneficial balance effect on hardness gradient and wear resistance distribution.

[0024] For example, the lifting support mechanism 6 is disposed inside the cooling box 2 and located directly below the induction heating ring 5, for supporting the trapezoidal gear and allowing it to move vertically. By controlling the lifting support mechanism 6, the trapezoidal gear can enter or exit the inner ring of the induction heating ring 5 vertically, allowing each trapezoidal tooth to enter the heating area of ​​the trapezoidal heating frame 51 in sequence. During the heating process, the trapezoidal gear gradually comes into contact with the trapezoidal heating frame 51 of the induction heating ring 5, generating eddy current losses and Joule heating under the influence of the induced current, thereby causing the temperature of the metal structure to rise uniformly to the temperature range required for quenching. After holding at this temperature for a certain period of time, it can be rapidly cooled in the liquid quenching medium of the cooling box 2. The liquid quenching medium can control the cooling rate to a certain extent, achieving a relative balance between hardness and toughness, reducing the risk of excessive deformation or cracking of the trapezoidal gear during quenching, while maintaining the overall stability of wear resistance and fatigue strength.

[0025] For example, the insulating component 8 is detachably connected to the conductive component 4. The position of the insulating component 8 prevents direct contact between the positive and negative currents in the conductive component 4, thereby reducing the possibility of short circuits to some extent. The insulating component 8 can be made of high-temperature resistant insulating plastic or high-temperature engineering polymer, so that it maintains its mechanical strength and insulation properties in the high-temperature environment of the quenching process.

[0026] For example, the connector 9 is used to fix the insulating component 8 to the conductive component 4, and when an abnormal short circuit occurs in the conductive component 4, it produces observable changes through local melting, alerting the operator to take timely operational measures. It is worth noting that the molten portion of the connector 9 is mainly used for visual cues and fault detection by the operator, while maintaining the physical connection between the insulating component 8 and the conductive component 4 during the melting process. This ensures that the device retains its functionality in terms of safety detection and mechanical support, thereby providing a certain degree of operational safety and device maintainability.

[0027] Understandably, during operation, liquid quenching medium is first poured into the cooling tank 2, and the quencher 3 is turned on to preheat the inner ring of the induction heating ring 5, so that the trapezoidal heating frame 51 reaches the required heating temperature. After the quenched trapezoidal gear is placed on the lifting support mechanism 6 and its position is adjusted, the trapezoidal gear is moved vertically upward by the lifting support mechanism 6, so that each trapezoidal tooth enters the corresponding trapezoidal heating frame 51 for heating. During the heating process, due to the well-matched contact relationship between the trapezoidal teeth and the trapezoidal heating frame 51, each tooth surface can receive heat, which helps to improve the differences in hardness and wear resistance distribution caused by uneven heating. After heating is completed, the trapezoidal gear is moved down into the liquid quenching medium by the lifting support mechanism 6 for rapid cooling, forming the desired quenched structure and hardness.

[0028] Based on this, through the above structure and operation, the trapezoidal heating frame 51, the lifting support mechanism 6, the insulating component 8, and the connecting component 9 work together to improve the electrical stability of the conductive component 4, the uniformity of induction heating, and the quenching quality of the trapezoidal gear to a certain extent. In particular, the matching design between the trapezoidal heating frame 51 and the trapezoidal gear tooth profile has a beneficial effect on the uniformity of gear surface hardness and wear resistance distribution; the setting of the insulating component 8 reduces the risk of short circuit between positive and negative currents to a certain extent; the partial melting of the connecting component 9 under short circuit abnormality provides a fault indication, while still maintaining the connection to the conductive component 4, thus having a certain beneficial effect on improving operational safety, device maintenance convenience, and the uniformity of gear quenching effect.

[0029] In some embodiments, combined with Figure 2 , Figure 3 and Figure 4 The conductive component 4 includes a positive electrode rod 41 and a negative electrode rod 42, which are arranged in parallel along the horizontal direction and a strip gap 43 is reserved between them.

[0030] For example, the insulating element 8 is installed within the strip gap 43, which to some extent separates the positive electrode rod 41 from the negative electrode rod 42. This reduces the risk of direct contact between the positive and negative electrodes when the conductive element 4 is energized, while not affecting the formation of a closed current loop in the induction heating ring 5. The width of the strip gap 43 and the dimensions of the insulating element 8 can be designed according to the cross-sectional area of ​​the conductive element 4 and the required current carrying capacity, so that the positive electrode rod 41 and the negative electrode rod 42 maintain relatively stable electrical performance when carrying the current passing through the induction heating ring 5.

[0031] It is understandable that the dual-rod design, with positive electrode rod 41 and negative electrode rod 42, has a certain advantage in load-bearing capacity compared to a single-rod structure. This allows the induction heating ring 5 to maintain a relatively stable position above the opening of the cooling box 2. Simultaneously, it reduces poor contact caused by bending or vibration of the conductive component 4 due to insufficient force during the lifting and lowering movement of the trapezoidal gear, thus contributing to the uniformity of heating. The insulating component 8, installed within the strip gap 43, can maintain the separation of positive and negative currents to a certain extent, thereby making the current transmission of the trapezoidal conductive frame 511 and the entire induction heating ring 5 more reliable. It also facilitates the even heating of each trapezoidal tooth during the heating process of the trapezoidal gear.

[0032] For example, one of the multiple trapezoidal heating frames 51 is a trapezoidal conductive frame 511, which includes a positive electrode sub-frame 5111 and a negative electrode sub-frame 5112, with a conductive gap 5113 reserved between them. This conductive gap 5113 is connected to the strip gap 43 along the length of the positive electrode rod 41, allowing the insulating member 8 to partially extend into the trapezoidal conductive frame 511. It is worth noting that the insertion depth and position of the insulating member 8 within the trapezoidal conductive frame 511 are adjusted so that while separating the positive electrode rod 41 and the negative electrode rod 42, the trapezoidal conductive frame 511 can still form a closed current path, realizing the normal heating function of the induction heating ring 5.

[0033] Meanwhile, the positive and negative sub-frames 5111 and 5112 of the trapezoidal conductive frame 511 are matched in shape and size to the tooth profile of the trapezoidal gear, ensuring that each trapezoidal tooth of the gear is fully heated after entering the trapezoidal conductive frame 511. This, to a certain extent, improves the uneven hardness and wear resistance of the trapezoidal gear tooth surface and root. The connection between the conductive notch 5113 and the strip gap 43 is beneficial for providing a fixed and guiding position for the insulating component 8 during heating, allowing the insulating component 8 to remain stable within the trapezoidal conductive frame 511, while maintaining effective isolation between the positive and negative currents when energized.

[0034] For example, the positive electrode frame 5111 and the negative electrode frame 5112 have arc-shaped protrusions 7 on their inner frame walls near the conductive notch 5113. These arc-shaped protrusions are arranged along the length of the strip gap 43. Compared to the straight inner frame walls of the positive electrode frame 5111 and the negative electrode frame 5112, the arc-shaped protrusions 7 provide a larger heating surface area, allowing the trapezoidal gear end face covered by the arc-shaped protrusions to obtain more uniform heat transfer. The straight-line distance 'a' between the arc-shaped protrusions 7 and the trapezoidal gear end wall is less than the straight-line distance 'b' between the end of the insulating member 8 and the trapezoidal gear end wall. Therefore, the arc-shaped protrusions form a closer heating surface near the trapezoidal gear tooth end face, which helps to compensate for the reduced heat transfer caused by the insulating member 8 occupying part of the inner wall space after extending into the trapezoidal conductive frame 511, thereby improving the heating uniformity of the trapezoidal gear to a certain extent. The geometric design of the arc-shaped protrusion 7 and the synergistic effect of the insertion depth of the insulating part 8 enable the trapezoidal gear to maintain the current path and electrical isolation during the heating process of entering the trapezoidal conductive frame 511, while also providing relatively balanced heating conditions for the trapezoidal teeth. This is conducive to a more balanced distribution of hardness and wear resistance of the trapezoidal gear on the tooth surface and tooth root.

[0035] Based on this, through the above structure, the dual-rod design of the positive electrode guide rod 41 and the negative electrode guide rod 42, the combination of the strip gap 43 and the insulating component 8, and the arrangement of the arc-shaped protrusion 7 inside the trapezoidal conductive frame 511 form a complete functional chain: the conductive component 4 maintains stability and electrical isolation when carrying current, the trapezoidal conductive frame 511 forms a closed current path during the heating process of the trapezoidal gear, and the arc-shaped protrusion 7 compensates for the heat reduction brought by the insulating component 8, thereby improving the heating uniformity of each trapezoidal tooth of the trapezoidal gear to a certain extent, and contributing to the balanced distribution of gear hardness, wear resistance, and fatigue strength throughout the entire quenching process. At the same time, this structural design also facilitates the inspection and maintenance of the conductive component 4 during operation, enabling the heating ring and the lifting support mechanism 6 to maintain a relatively stable mechanical and electrical state when working together, thus providing a reliable structural and functional foundation for the quenching of the trapezoidal gear.

[0036] In some examples, such as Figure 2 , Figure 3 and Figure 4 As shown, the insulating component 8 is made of alumina ceramic plate 81. The length of the alumina ceramic plate 81 is designed to be greater than the sum of the lengths of the strip gap 43 and the conductive notch 5113. The thickness of the alumina ceramic plate 81 is less than the horizontal width of the strip gap 43, while the width of the alumina ceramic plate 81 is greater than the vertical width of the strip gap 43.

[0037] It is understandable that during the installation process, the alumina ceramic plate 81 is embedded in the strip gap 43, and both the upper and lower ends of the alumina ceramic plate 81 are exposed outside the strip gap 43. This allows it to effectively prevent the positive electrode rod 41 from contacting the negative electrode rod 42 while separating the positive electrode rod 41 from the negative electrode rod 42, and also forms a coordinated electrical layout with the trapezoidal conductive frame 511.

[0038] Meanwhile, the insulating component 8 is made of alumina ceramic plate 81. Alumina ceramic material has high temperature resistance and insulation strength, and can withstand the high temperature environment generated by the induction heating ring 5 during the quenching process of the trapezoidal gear without deformation or a decrease in insulation performance, thereby ensuring the stability of the current conduction path of the conductive component 4 to a certain extent. The thickness of the alumina ceramic plate 81 is less than the transverse width of the strip gap 43, which allows the alumina ceramic plate 81 to be properly inserted into the strip gap 43. At the same time, it allows the conductive component 4 to maintain an appropriate contact area when conducting current, which is beneficial to the formation of a stable current loop in the induction heating ring 5, and at the same time, it does not restrict heat transfer due to the excessive thickness of the insulating component 8.

[0039] In some implementations, combined Figure 3 , Figure 4 and Figure 5 The connector 9 includes a low-melting-point polymer cable tie 91 and an insulating wire 92. The low-melting-point polymer cable tie 91 is circumferentially and tightly sleeved on the outer surface of the conductive component 4 and the alumina ceramic plate 81, while the insulating wire 92 is tightly wrapped around the outer surface of the low-melting-point polymer cable tie 91 to further fix the alumina ceramic plate 81 in the strip gap 43, so that it maintains a stable position in the trapezoidal conductive frame 511 and the strip gap 43.

[0040] For example, the low-melting-point polymer cable tie 91 can be made of polyethylene or polypropylene, which have relatively low melting points and are less likely to generate open flames during the melting process. Melt residue can enter the quenching liquid in the cooling tank 2, minimizing its impact on equipment safety. The insulating wire 92 is formed by coating PVC or specially chemically treated glass fiber composite material onto a galvanized iron wire substrate. It possesses high electrical resistance, high temperature resistance, and a low coefficient of friction, thus providing a certain constraint force on the low-melting-point polymer cable tie 91 during the quenching process of the trapezoidal gear, while maintaining structural stability when the conductive component 4 experiences a short circuit. In other words, even after the low-melting-point polymer cable tie 91 melts when the conductive component 4 or the entire heating circuit experiences a short circuit, the insulating wire 92 can still effectively fix the insulating component 8 within the strip gap 43, preventing the insulating component 8 from being affected by the melting of the low-melting-point polymer cable tie 91.

[0041] It is worth noting that, in the appendix Figure 4 In order to demonstrate the positional relationship between the various components, insulating wire 92 is used. Figure 4As can be seen above, the low-melting-point polymer cable ties 91 separate the conductive component 4 and the alumina ceramic plate 81. However, in actual working conditions, the low-melting-point polymer cable ties 91 are relatively thinner. The insulating wire 92 actually applies force to the low-melting-point polymer cable ties 91 and tightly binds them to the conductive component 4 and the alumina ceramic plate 81. That is, the thickness of the low-melting-point polymer cable ties 91 is not... Figure 4 The thickness shown is not as thick as it appears, but rather relatively thinner, so that even after the low-melting-point polymer cable tie 91 has partially melted, the insulating wire 92 can still effectively tighten the conductive component 4 and the alumina ceramic plate 81.

[0042] For example, the low-melting-point polymer cable tie 91, the conductive element 4, and the alumina ceramic plate 81 are combined to form four triangular isolation cavities 10. The presence of the triangular isolation cavities 10 helps to separate the low-melting-point polymer cable tie 91 from the strip gap 43, preventing the low-melting-point polymer cable tie 91 from melting under normal operating conditions due to the normal heat generated by the current flowing through the strip gap 43. The spatial arrangement and geometry of the triangular isolation cavities 10 establish a clear correspondence between the thermal melting behavior of the low-melting-point polymer cable tie 91 and the abnormal state of the device. When the conductive element 4 or the entire heating circuit experiences a short circuit, the temperature of the conductive element 4 rises sharply. The heat is conducted through contact to the low-melting-point polymer cable tie 91, which is in close contact with its outer surface. This causes the low-melting-point polymer cable tie 91 to partially melt under high temperature, thus alerting the operator to an abnormality in the device through an observable phenomenon, requiring immediate power disconnection. The triangular isolation cavity 10 provides a certain thermal insulation protection for the low melting point polymer cable tie 91 in space, so that it is not affected by the heat generated by the normal current inside the strip gap 43, thereby avoiding misjudgment of equipment failure. At the same time, when a real failure occurs in the device, the thermal melting behavior of the low melting point polymer cable tie 91 can more intuitively prompt the operator to intervene.

[0043] It is worth noting that when the low-melting-point polymer cable tie 91 is wrapped around the outer surface of the conductive component 4 and the alumina ceramic plate 81, its melting upon heating will, to some extent, reflect the temperature rise of the conductive component 4. Because polyethylene or polypropylene cable ties have low melting points and are less likely to produce open flames when melting, the low-melting-point polymer cable tie 91 can melt in time when the conductive component 4 experiences a short circuit and rapid temperature rise, allowing operators to visually judge the equipment's operating status. The presence of the insulating wire 92 provides a certain mechanical constraint while tightening the low-melting-point polymer cable tie 91, ensuring the alumina ceramic plate 81 remains stable within the strip gap 43. This prevents the insulating component 8 from shifting or falling off significantly after the low-melting-point polymer cable tie 91 melts, thereby maintaining the positive and negative electrode isolation of the conductive component 4 and the integrity of the current circuit. The structure formed by the low-melting-point polymer cable tie 91, the conductive component 4, and the alumina ceramic plate 81 can also conduct feedback on the surface temperature change of the conductive component 4 to a certain extent, so that the abnormal temperature is concentrated in the area of ​​the low-melting-point polymer cable tie 91 and the insulating wire 92, thereby limiting the safety warning to the observable range and reducing the thermal impact on other components.

[0044] Through the above design, the low-melting-point polymer cable ties 91, insulating wires 92, conductive components 4, and alumina ceramic plates 81 form a stable and feedback-enabled structural system. This system provides intuitive safety alerts when the conductive components 4 or heating circuit experiences abnormal temperature rise, while maintaining stable current transmission in the conductive components 4 and the isolation function of the alumina ceramic plates 81 under normal operating conditions. Simultaneously, the triangular isolation cavity 10 further reduces the risk of misjudgment, ensuring the entire trapezoidal gear quenching device possesses a certain degree of safety redundancy and structural reliability during operation. Throughout the quenching process, the low-melting-point polymer cable ties 91 will not ignite upon thermal melting, and their residue can be disposed of through the coolant circulation, posing no fire hazard to the cooling system. Furthermore, this facilitates timely fault detection and mitigation by operators, thereby improving the controllability and safety of the quenching device's operation.

[0045] Meanwhile, cooling quenching fluids can be cooling water, polymer quenching fluids, etc. Polymer quenching fluids can also be PAG aqueous solutions, typically solutions of polyalkylene alcohol or polyvinyl alcohol in water. At the same time, the main component of polymer quenching fluid is water (usually 80~95%), and polymer accounts for only a small amount (5~20%). Therefore, it is not easily ignited by the residues that fall off after the low-melting-point polymer cable ties 91 are melted.

[0046] In some implementations, combined with Figure 1 , Figure 6The lifting support mechanism 6 includes a cylinder 61, a mounting base 62, and a positioning column 63. The cylinder 61 is fixed to the inner bottom wall of the cooling box 2, and the piston rod of the cylinder 61 extends vertically. The mounting base 62 is installed on the top of the piston rod, and the positioning column 63 is located at the center of the upper surface of the mounting base 62. The size of the positioning column 63 matches the inner ring of the trapezoidal gear, so that the trapezoidal gear can be fixed on the lifting support mechanism 6 by means of plug-in engagement.

[0047] For example, the cylinder 61 is a waterproof type, meaning it is not easily affected by the cooling quenching fluid in the cooling box 2 and will not lose its driving effect.

[0048] It is understood that when the cylinder 61 is working, it drives the piston rod to move vertically and retract through compressed gas, which in turn drives the mounting base 62 and the positioning column 63 to rise and fall, thereby controlling the position change of the trapezoidal gear inside the cooling box 2. After the heating process is completed, the lifting support mechanism 6 can drive the trapezoidal gear to move down, allowing it to enter the coolant for rapid cooling. Before the heating process begins, the lifting support mechanism 6 can lift the trapezoidal gear to the upper opening position of the cooling box 2, so that the induction heating ring 5 and the trapezoidal gear form an effective heating area. The positioning column 63 can be inserted and engaged with the inner ring of the trapezoidal gear, which helps to maintain the stability of the trapezoidal gear's posture during the lifting process, thereby preventing the trapezoidal gear from tilting during the downward or upward movement and ensuring the relative positional accuracy of the trapezoidal gear between the induction heating ring 5 and the cooling box 2.

[0049] Meanwhile, the cylinder 61 provides high controllability for the lifting action. The vertical extension direction of the piston rod of the cylinder 61 clearly transmits force, and the mounting base 62, as a connecting component, provides a stable transition between the piston rod and the positioning column 63. It can bear the weight of the trapezoidal gear and evenly transmit the output force of the cylinder 61 to the positioning column 63. The positioning column 63 is located at the center of the upper surface of the mounting base 62, ensuring symmetrical force distribution and preventing the trapezoidal gear from shaking due to uneven force distribution. Through this structure, the trapezoidal gear can quickly switch between the induction heating and cooling processes, ensuring the continuity and efficiency of the quenching process. At the same time, the lifting support mechanism 6 can also reduce the labor intensity of manual handling to a certain extent and improve the safety and consistency of the workpiece during the quenching process. Overall, the combined design of the cylinder 61, mounting base 62, and positioning column 63 forms a complete lifting support system in terms of structure and function, which is beneficial to improving the process stability of the trapezoidal gear quenching process and also to improving the automation level of equipment operation.

[0050] Second page, refer to Figures 1 to 6 This application provides a quenching method for gearbox gears, implemented based on the gearbox gear quenching apparatus of the first aspect, comprising the following steps: Pour the cooling quenching fluid into cooling tank 2; Turn on the quencher 3 to preheat the inner ring of the induction heating ring 5; Place the trapezoidal gear to be quenched onto the lifting support mechanism 6, and adjust the position of the trapezoidal gear so that each trapezoidal tooth of the trapezoidal gear is directly opposite a trapezoidal heating frame 51. Start the lifting support mechanism 6 to vertically move the trapezoidal gear to be quenched to the inner ring of the induction heating ring 5, and each trapezoidal tooth of the trapezoidal gear enters a trapezoidal heating frame 51 for heating. The lifting support mechanism 6 is restarted, causing the heated trapezoidal gear to move vertically downwards into the cooling quenching liquid below its surface, completing the quenching process. In the description of this application, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, features defined with "first" and "second" may explicitly or implicitly include one or more features. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0051] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions of other embodiments.

[0052] The embodiments, implementation methods, and related technical features of this application can be combined and substituted for each other without conflict.

[0053] The above are merely preferred embodiments of this application and are not intended to limit this application in any way. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of this application without departing from the technical solution of this application shall still fall within the scope of the technical solution of this application.

Claims

1. A gearbox gear quenching device, characterized in that, include: Body (1); A cooling box (2) is installed on the body (1), and the interior of the cooling box (2) is hollow and the upper end is open; The quencher (3), conductive element (4), and induction heating ring (5) are mounted on the machine body (1) and located on one side of the cooling box (2). The first end of the conductive element (4) is electrically connected to the quencher (3), and the second end of the conductive element (4) extends horizontally above the opening of the cooling box (2). The induction heating ring (5) is electrically connected to the second end of the conductive element (4). The induction heating ring (5) has multiple trapezoidal heating frames (51) convex outward around the circumference. Each trapezoidal heating frame (51) is configured to be adapted to a trapezoidal tooth of a trapezoidal gear. The lifting support mechanism (6) is installed inside the cooling box (2) and located directly below the induction heating ring (5). The lifting support mechanism (6) is configured to place the trapezoidal gear and drive the trapezoidal gear to move in the vertical direction to enter or exit the inner ring of the induction heating ring (5). An insulating component (8) is detachably connected to the conductive component (4). The insulating component (8) is used to block the positive current and negative current on the conductive component (4). The insulating component (8) is an alumina ceramic plate (81). A connector (9) is disposed on the conductive member (4) and is configured to fix the insulating member (8) to the conductive member (4) and to partially melt when a short circuit occurs in the conductive member (4); The connector (9) includes a low-melting-point polymer cable tie (91) and an insulating wire (92). The low-melting-point polymer cable tie (91) is circumferentially and tightly sleeved on the outer surface of the conductive component (4) and the alumina ceramic plate (81). The insulating wire (92) is tightly wrapped around the outer surface of the low-melting-point polymer cable tie (91) and is used to secure the alumina ceramic plate (81) within the strip gap (43).

2. The gearbox gear quenching device according to claim 1, characterized in that, The conductive component (4) includes a positive electrode rod (41) and a negative electrode rod (42). The positive electrode rod (41) and the negative electrode rod (42) are parallel and a strip gap (43) is reserved between them. The insulating component (8) is installed in the strip gap (43). One of the multiple trapezoidal heating frames (51) is a trapezoidal conductive frame (511). The first end of the positive electrode rod (41) is electrically connected to the positive electrode of the quencher (3), and the second end is connected to the trapezoidal conductive frame (511). The first end of the negative electrode rod (42) is electrically connected to the negative electrode of the quencher (3), and the second end is connected to the trapezoidal conductive frame (511).

3. The gearbox gear quenching device according to claim 2, characterized in that, The trapezoidal conductive frame (511) includes a positive electrode sub-frame (5111) and a negative electrode sub-frame (5112). A conductive gap (5113) is reserved between the positive electrode sub-frame (5111) and the negative electrode sub-frame (5112). The conductive gap (5113) communicates with the strip gap (43). The insulating member (8) is configured to extend into the trapezoidal conductive frame (511) via the conductive gap (5113).

4. The gearbox gear quenching device according to claim 3, characterized in that, Both the positive electrode sub-frame (5111) and the negative electrode sub-frame (5112) have arc-shaped protrusions (7) on their inner frame walls near the conductive gap (5113). Along the length direction of the strip gap (43), the longest straight-line distance between the arc-shaped protrusion (7) and the end wall of the trapezoidal gear in the trapezoidal conductive frame (511) is configured as a, and the shortest straight-line distance between the end of the insulating member (8) and the end wall of the trapezoidal gear in the trapezoidal conductive frame (511) is configured as b, where a < b.

5. The gearbox gear quenching device according to claim 3, characterized in that, The length of the alumina ceramic plate (81) is greater than the sum of the lengths of the strip gap (43) and the conductive notch (5113), the thickness of the alumina ceramic plate (81) is less than the lateral width of the strip gap (43), and the width of the alumina ceramic plate (81) is greater than the vertical width of the strip gap (43). The alumina ceramic plate (81) is configured such that when it is embedded in the strip gap (43), both the upper and lower ends of the alumina ceramic plate (81) are exposed outside the strip gap (43).

6. The gearbox gear quenching device according to claim 1, characterized in that, The low-melting-point polymer cable tie (91), the conductive element (4), and the alumina ceramic plate (81) form four triangular isolation cavities (10), which are used to separate the low-melting-point polymer cable tie (91) from the strip gap (43).

7. The gearbox gear quenching apparatus according to claim 6, characterized in that, The low-melting-point polymer cable tie (91) is a polyethylene cable tie or a polypropylene cable tie.

8. The gearbox gear quenching apparatus according to any one of claims 1 to 7, characterized in that, The lifting support mechanism (6) includes a cylinder (61), a mounting base (62), and a positioning column (63). The cylinder (61) is mounted on the inner bottom wall of the cooling box (2), and the piston rod of the cylinder (61) extends vertically. The mounting base (62) is located at the top of the piston rod of the cylinder (61), and the positioning column (63) is located at the center of the upper surface of the mounting base (62) and is configured to engage with the inner ring of the trapezoidal gear.

9. A quenching method for gearbox gears, characterized in that, Based on the gearbox gear quenching apparatus according to any one of claims 1 to 8, the process includes the following steps: Pour cooling quenching fluid into the cooling tank (2); Turn on the quencher (3) to preheat the inner ring of the induction heating ring (5); Place the trapezoidal gear to be quenched onto the lifting support mechanism (6) and adjust the position of the trapezoidal gear so that each trapezoidal tooth of the trapezoidal gear is directly opposite a trapezoidal heating frame (51). Start the lifting support mechanism (6) to vertically move the trapezoidal gear to be quenched to the inner ring of the induction heating ring (5), and each trapezoidal tooth of the trapezoidal gear enters a trapezoidal heating frame (51) for heating; Restart the lifting support mechanism (6) to drive the heated trapezoidal gear to move vertically down into the cooling quenching liquid below the liquid surface, and complete the quenching.

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