Angle automatic compensation device for inductor of bearing induction heating integral quenching equipment

Abstract

The utility model discloses an automatic angle compensation device for a sensor of bearing induction heating integral quenching equipment, which is characterized in that a laser distance sensor is arranged at the upper part of the outer wall of a side plate of a transformer mounting rack, a detection plate is arranged at the bottom of a sensor frame, and a rotating shaft is horizontally and rotatably arranged between the side plates at the two sides of the transformer mounting rack; a driving mechanism is fixedly arranged on the outer wall of a side plate of the transformer mounting frame, a distance signal detected by the laser distance sensor is input into the PLC, and the driving mechanism is controlled through a PLC program to adjust the angle position of the inductor; the device is compact and reasonable in structural design, the angle of the inductor is accurately and automatically compensated and adjusted in real time through PLC control, the distance between an induction coil and the surface of a workpiece is kept relatively stable, the induction coil is prevented from touching the workpiece, and the problem that the distance between the inductor and the workpiece is inconsistent due to magnetic moment in the heating process of induction equipment is solved; the uniformity during induction heating is ensured, the operation stability of induction heating equipment is improved, and the heat treatment quality of products is improved.

Description

Technical Field

[0001] This utility model belongs to the field of bearing induction hardening heat treatment technology, specifically relating to an automatic compensation device for the inductor angle of a bearing induction heating integral hardening equipment. Background Technology

[0002] To adapt to the development of larger megawatt wind turbines in the wind power bearing industry, improve the efficiency of heat treatment processing of wind power bearings, and reduce production costs, a new type of induction heating integral quenching equipment has been developed. This equipment is used for induction heating integral quenching heat treatment of workpieces such as wind turbine main bearing rings. However, during the heating process, the alternating magnetic field causes the inductor to be attracted by the workpiece. The inductor frame deforms due to the strong magnetic force, resulting in the lower part of the inductor being closer to the workpiece surface due to different lever arms at different heights. At the same time, the magnitude of the magnetic force is related to the induction heating current and the distance between the coil and the workpiece surface. The larger the current, the stronger the magnetic force; the closer the distance, the stronger the magnetic force. Therefore, the distance between the inductor coil and the workpiece surface is inconsistent at different heights, and the distance changes with the heating current. The closer the inductor coil is to the workpiece surface, the higher the heating intensity and the faster the workpiece heats up. This leads to different heating rates on the workpiece surface, affecting the uniformity of workpiece heating and ultimately affecting product quality. In addition, when the distance between the induction coil and the workpiece surface is small, there is a risk that the induction coil may touch the workpiece when the workpiece is rotated and heated. Once it touches the workpiece, it is very likely to cause arcing and shutdown, or even damage to the sensor or scrap the workpiece.

[0003] In order to better control the induction heating process, ensure the relative stability of the distance between the induction coil and various parts of the workpiece, and ensure the uniformity of workpiece heating, there is an urgent need for an automatic compensation device for the inductor angle of the bearing induction heating integral quenching equipment. Summary of the Invention

[0004] To address the aforementioned technical problems, this invention provides an automatic compensation device for the inductor angle of a bearing induction heating integral quenching equipment. This device adjusts the inductor angle in real time to improve the problem of inconsistent inductor-to-workpiece distance caused by magnetic torque during the heating process. It maintains a relatively stable distance between the induction coil and the workpiece surface, ensuring uniform heating of the workpiece during induction heating. Simultaneously, it eliminates the risk of touching the inductor, improves the stability of the induction heating equipment, reduces product rework, and even inductor damage and product scrap, thus guaranteeing the quality of the heat treatment.

[0005] The technical solution adopted by this utility model is: an automatic compensation device for the sensor angle of a bearing induction heating integral quenching equipment. The induction heating integral quenching equipment is equipped with a moving robotic arm and a lifting robotic arm. A transformer mounting frame is fixedly installed at the bottom of the lifting robotic arm through a connecting block. A transformer is installed inside the transformer mounting frame. A sensor frame and a sensor are provided at the lower part of the transformer mounting frame. A laser distance sensor is installed on the upper part of the outer wall of the side plate of the transformer mounting frame. A detection plate is installed at the bottom of the sensor frame. A connecting arm is fixedly installed on the lower side of one side of the transformer housing. A connecting frame is fixedly installed on the top of the sensor frame. The lower part of the connecting arm is engaged with the connecting frame at the top of the sensor frame. A rotating shaft is horizontally rotatably installed between the two side plates of the transformer mounting frame. The rotating shaft passes through the transformer housing and is fixedly connected to the transformer housing. A drive mechanism is fixedly installed on the outer wall of the side plate of the transformer mounting frame. One end of the rotating shaft is coaxially connected to the output shaft of the drive mechanism. The distance signal detected by the laser distance sensor is input into the PLC. The PLC program controls the drive mechanism to adjust the angle position of the sensor.

[0006] The detection plate is attached to the bottom surface of the sensor frame base plate and extends horizontally outward away from the induction heating side. The detection plate extends to the outside of the left side of the sensor frame. The length of the detection plate is adapted to the installation position of the laser distance sensor. The laser distance sensor emits a signal vertically downward and hits the laser detection position on the detection plate.

[0007] The connecting frame includes a vertically arranged connecting plate. Right-angled triangular ribs are fixedly arranged at intervals on one side of the connecting plate. One right-angled side of the rib is fixedly connected to the connecting plate, and the other right-angled side of the rib is fixedly connected to the upper surface of the sensor frame. A sensor copper tube is provided on the right side of the sensor.

[0008] The connecting arm is provided in at least two parts. The lower inner side of the connecting arm is provided with a concave groove. The length and depth of the concave groove are adapted to the width and thickness of the connecting plate, respectively. The connecting arm is engaged with the connecting plate of the connecting frame through the groove.

[0009] The drive mechanism includes a servo motor and a worm gear reducer. The servo motor outputs torque by reducing the speed of the worm gear reducer, and the output shaft of the worm gear reducer transmits the torque to the rotating shaft through a coupling.

[0010] The laser distance sensor and servo motor are both electrically connected to the PLC controller. The PLC's sensor angle automatic adjustment control program controls the transmission mechanism, which drives the rotation shaft and sensor to rotate, and automatically compensates and adjusts the sensor angle position.

[0011] The laser distance sensor uses high-precision equipment, with a detection accuracy of ±0.02mm.

[0012] A laser distance sensor is installed on the upper part of the outer wall of the side plate of the transformer mounting bracket. A detection plate is installed at the bottom of the sensor frame. A connecting arm is fixedly installed on the lower side of one side of the transformer housing, and a connecting frame is fixedly installed on the top of the sensor frame. The lower part of the connecting arm is engaged with the connecting frame at the top of the sensor frame. The purpose of this arrangement is to ensure a stable connection through the engagement of the connecting arm and the connecting plate. The distance signal change detected by the high-precision laser distance sensor is transmitted to the PLC program to control the drive mechanism to drive the rotating shaft to rotate. The angle is automatically compensated and adjusted more smoothly and with higher precision. This allows for automatic tracking and detection of the distance gap change between the sensor and the workpiece during the quenching process, automatically compensating for the angle deformation. The gap deviation between the workpiece and the sensor is automatically tracked and compensated by the transformer rotation servo motor for precise adjustment, ensuring that the gap between the sensor copper tube and the workpiece remains consistent in real time, resulting in uniform heating and thus guaranteeing the quality of induction heating of the workpiece.

[0013] The drive mechanism includes a servo motor and a worm gear reducer. The servo motor outputs torque through the worm gear reducer, and the output shaft of the worm gear reducer transmits the torque to the rotating shaft via a coupling. This arrangement is intended to address the following: A servo motor is a generator that controls the operation of mechanical components in a servo system; it is a type of auxiliary motor with indirect speed change. Servo motors offer highly accurate speed and position control, converting voltage signals into torque and speed to drive the controlled object. The rotor speed of the servo motor is controlled by the input signal and can respond quickly. In automatic control systems, it serves as an actuator and possesses characteristics such as a small electromechanical time constant, high linearity, and low starting voltage. It can convert received electrical signals into angular displacement or angular velocity output on the motor shaft. The drive mechanism of the servo motor and worm gear reducer is easy to connect and install, offers high control precision, and uses a PLC-based sensor angle automatic adjustment control program to control the transmission mechanism, driving the rotation of the rotating shaft and the sensor, and automatically compensating for and adjusting the sensor angle position.

[0014] The beneficial effects of this utility model are as follows: The automatic sensor angle compensation device has a compact and reasonable structural design. It uses a transmission mechanism composed of a high-precision laser sensor, a servo motor, and a worm gear reducer. Controlled by the automatic sensor angle adjustment control program of the PLC, it accurately performs real-time automatic compensation and adjustment of the sensor angle position, maintains the relative stability of the distance between the induction coil and the workpiece surface, avoids the induction coil from touching the workpiece, ensures the uniformity of induction heating, improves the stability of the induction heating equipment, reduces product rework, sensor damage, and product scrap caused by this, and improves the heat treatment quality of the product. Attached Figure Description

[0015] Figure 1 This is a top view schematic diagram of the overall structure of the sensor angle compensation device of this utility model;

[0016] Figure 2 This is a schematic diagram of the sensor structure of the sensor angle compensation device of this utility model;

[0017] Figure 3 This is a schematic diagram of the angle adjustment mechanism of the sensor angle compensation device of this utility model.

[0018] The markings in the diagram are: 1. Moving robotic arm; 2. Lifting robotic arm; 3. Transformer mounting bracket; 4. Sensor frame; 5. Sensor; 6. Base plate; 7. Laser distance sensor; 8. Detection plate; 9. Servo motor; 10. Worm gear reducer; 11. Connecting arm; 12. Slot; 13. Rotating shaft; 14. Connecting frame; 15. Connecting plate; 16. Rib plate; 17. Workpiece; 18. Connecting block. Detailed Implementation

[0019] The specific embodiments of this utility model will be further described in detail below with reference to the accompanying drawings.

[0020] like Figure 1-3 As shown, an automatic compensation device for the sensor angle of a bearing induction heating integral quenching equipment is disclosed. The induction heating integral quenching equipment is equipped with a moving robotic arm 1 and a lifting robotic arm 2. A transformer mounting frame 3 is fixedly installed at the bottom of the lifting robotic arm 2 via a connecting block 18. A transformer is installed inside the transformer mounting frame 3. A sensor frame 4 and a sensor 5 are provided at the lower part of the transformer. A laser distance sensor 7 is installed on the upper part of the outer wall of the side plate of the transformer mounting frame 3. A detection plate 8 is installed at the bottom of the sensor frame 4. A connecting arm 11 is fixedly installed on the lower side of one side of the transformer housing. A connecting frame 14 is fixedly installed on the top of the sensor frame 3. The lower part of the connecting arm 11 is engaged with the connecting frame 14. A rotating shaft 13 is horizontally rotatably installed between the two side plates of the transformer mounting frame 3. The rotating shaft 13 passes through the transformer housing and is fixedly connected to the transformer housing. A drive mechanism is fixedly installed on the outer wall of the side plate of the transformer mounting frame 3. One end of the rotating shaft 13 is coaxially connected to the output shaft of the drive mechanism. The distance signal detected by the laser distance sensor 7 is input into the PLC. The PLC program controls the drive mechanism to adjust the angle position of the sensor 5.

[0021] The detection plate 8 is attached to the bottom surface of the sensor frame base plate 6 and extends horizontally outward away from the induction heating side. The detection plate 8 extends to the left side of the sensor frame 4. The length of the detection plate 8 is adapted to the installation position of the laser distance sensor 7. The laser distance sensor 7 emits a signal vertically downward to hit the laser detection position on the detection plate 8.

[0022] The connecting frame 14 includes a vertically arranged connecting plate 15. Right-angled triangular ribs 16 are fixedly arranged at intervals on one side of the connecting plate 15. One right-angled side of the rib 16 is fixedly connected to the connecting plate 15, and the other right-angled side of the rib 16 is fixedly connected to the upper surface of the sensor frame 4. A sensor copper tube is provided on the right side of the sensor 5.

[0023] At least two connecting arms 11 are provided. The lower inner side of the connecting arm 11 is provided with a concave groove 12. The length and depth of the concave groove 12 are adapted to the width and thickness of the connecting plate 15, respectively. The connecting arm 11 is engaged with the connecting plate 15 of the connecting frame 14 through the groove 12.

[0024] The drive mechanism includes a servo motor 9 and a worm gear reducer 10. The servo motor 9 outputs torque by reducing the speed of the worm gear reducer 10, and the output shaft of the worm gear reducer 10 transmits the torque to the rotating shaft 13 through a coupling.

[0025] The laser distance sensor 7 and servo motor 9 are both electrically connected to the PLC controller. The PLC's sensor angle automatic adjustment control program controls the transmission mechanism, which drives the rotation of the rotating shaft 13 and the sensor 5, and automatically compensates and adjusts the angle position of the sensor 5.

[0026] The laser distance sensor 7 is a high-precision device with a detection accuracy of ±0.02mm.

[0027] When the bearing induction heating integral quenching equipment is working, the position of the inductor 5 is adjusted by moving the mechanical arm 1 and the lifting mechanical arm 2 laterally and longitudinally to get closer to the workpiece 17 for heating. A transformer mounting bracket 3 and a transformer are installed below the lifting mechanical arm 2. The heating inductor 5 is located at the bottom of the transformer, and the transformer provides power to the heating inductor 5. During induction heating, the magnetic torque causes the sensor 5 to move closer to the workpiece 17. The detection plate 8, mounted on the sensor frame base plate 6, also shifts. At this point, the high-precision laser distance sensor 7 detects the change in distance between itself and the detection plate 8. The PLC program issues a command to start the servo motor 9. The servo motor 9 outputs torque through the worm gear reducer 10, driving the rotating shaft 13 to rotate in the opposite direction. The rotating shaft 13 drives the transformer housing, connecting arm 11, and sensor 5 to rotate in the opposite direction by a certain angle. In other words, the servo motor 9 starts and controls the sensor 5 to rotate in the opposite direction by a certain angle. When the distance detected by the laser distance sensor 7 is consistent with the initial distance, the PLC controls the servo motor 9 to stop rotating. At this point, the distance between the induction coil of sensor 5 and the surface of workpiece 17 at different heights is basically consistent. This demonstrates the continuous and efficient detection by the laser and the PLC... The program's rapid response can adjust the angle of sensor 5 in real time and make automatic compensation, maintaining a relatively stable distance between the induction coil and the surface of workpiece 17, avoiding the induction coil from touching the workpiece, ensuring uniformity during induction heating, improving the stability of the induction heating equipment, reducing product rework, sensor damage, and product scrap caused by this, and improving the quality of product heat treatment.

[0028] In addition to the above embodiments, this utility model may have other implementation methods. All technical solutions formed by equivalent substitution or equivalent transformation fall within the protection scope claimed by this utility model.

Claims

1. An automatic compensation device for the inductor angle of a bearing induction heating integral quenching equipment, wherein the induction heating integral quenching equipment is provided with a moving robotic arm and a lifting robotic arm, a transformer mounting bracket is fixedly installed at the bottom of the lifting robotic arm via a connecting block, a transformer is installed inside the transformer mounting bracket, and an inductor frame and an inductor are provided at the lower part of the transformer mounting bracket, characterized in that: A laser distance sensor is installed on the upper part of the outer wall of the side plate of the transformer mounting bracket. A detection plate is installed at the bottom of the sensor frame. A connecting arm is fixedly installed on the lower side of one side of the transformer housing. A connecting frame is fixedly installed on the top of the sensor frame. The lower part of the connecting arm is engaged with the connecting frame on the top of the sensor frame. A rotating shaft is horizontally and rotatably installed between the two side plates of the transformer mounting bracket. The rotating shaft passes through the transformer housing and is fixedly connected to the transformer housing. A drive mechanism is fixedly installed on the outer wall of the side plate of the transformer mounting bracket. One end of the rotating shaft is coaxially connected to the output shaft of the drive mechanism. The distance signal detected by the laser distance sensor is input into the PLC. The PLC program controls the drive mechanism to adjust the angle position of the sensor.

2. The automatic compensation device for the inductor angle of a bearing induction heating integral quenching equipment according to claim 1, characterized in that: The detection plate is attached to the bottom surface of the sensor frame base plate and extends horizontally outward away from the induction heating side. The detection plate extends to the left side of the sensor frame. The length of the detection plate is adapted to the installation position of the laser distance sensor. The laser distance sensor emits a signal vertically downward and hits the laser detection position on the detection plate.

3. The automatic compensation device for the inductor angle of a bearing induction heating integral quenching equipment according to claim 1, characterized in that: The connecting frame includes a vertically arranged connecting plate. Right-angled triangular ribs are fixedly arranged at intervals on one side of the connecting plate. One right-angled side of the rib is fixedly connected to the connecting plate, and the other right-angled side of the rib is fixedly connected to the upper surface of the sensor frame. A sensor copper tube is provided on the right side of the sensor.

4. The automatic compensation device for the inductor angle of a bearing induction heating integral quenching equipment according to claim 1, characterized in that: There are at least two connecting arms. The lower inner side of the connecting arm is provided with a concave groove. The length and depth of the concave groove are adapted to the width and thickness of the connecting plate, respectively. The connecting arm is engaged with the connecting plate of the connecting frame through the groove.

5. The automatic compensation device for the inductor angle of a bearing induction heating integral quenching equipment according to claim 1, characterized in that: The drive mechanism includes a servo motor and a worm gear reducer. The servo motor outputs torque by reducing the speed of the worm gear reducer, and the output shaft of the worm gear reducer transmits the torque to the rotating shaft through a coupling.

6. The automatic compensation device for the inductor angle of a bearing induction heating integral quenching equipment according to claim 1, characterized in that: The laser distance sensor and servo motor are electrically connected to the PLC controller. The PLC's sensor angle automatic adjustment control program controls the transmission mechanism, which drives the rotation shaft and sensor to rotate, and automatically compensates and adjusts the sensor angle position.

7. The automatic compensation device for the inductor angle of a bearing induction heating integral quenching equipment according to claim 1, characterized in that: The laser distance sensor uses high-precision equipment, with a detection accuracy of ±0.02mm.

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