Induction Hardening Tool Cooling System for Cylinder Deformation
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Solution Overview
Problem
Induction hardening tools for cylinders have short lifespans when using low frequencies, leading to mechanical deformation and increased production costs, with existing solutions failing to effectively extend tool life and achieve desired hardened layer thickness and quality.
Innovation Solution
A tool with a cooling system that includes a cooling channel within the inductor and console, a reservoir for cooling water, and temperature and flow sensors to monitor and control the cooling process, preventing mechanical deformation and allowing for deeper and higher-quality hardened layers using low frequencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If low frequency voltage is used for induction hardening of large diameter cylinders, then the depth of hardened layer increases, but the lifespan of inductor and console decreases due to mechanical deformation
Solution Approach 1:
The patent applies local quality by providing reinforcement elements (rigidening ribs, reinforcement rings, and reinforcement brackets) at specific critical locations on the inductor and console structures. These reinforcements are strategically placed in areas subjected to highest mechanical stress during low-frequency operation, strengthening only the necessary local regions without increasing overall device complexity or cost.
Solution Approach 2:
The patent employs composite construction by combining different structural elements - the inductor consists of copper winding on a non-magnetic core, the console integrates steel structural components with copper electrical contacts, and reinforcement elements are attached to existing structures. This composite approach allows optimization of each component for its specific function while maintaining overall structural integrity under low-frequency mechanical stress.
2Manufacturing precision
If low frequency voltage is used for induction hardening, then the quality of tempered layer structure improves, but mechanical damage to inductor console or inductor occurs
Solution Approach 1:
The patent implements preliminary anti-action by pre-installing reinforcement elements (rigidening ribs, reinforcement rings, and reinforcement brackets) on the inductor and console before operation. These reinforcements are designed to counteract the mechanical deformation forces that occur during low-frequency induction hardening, preventing damage before it occurs and allowing sustained use of low frequencies for high-quality hardening.
3Productivity
If inductor is damaged during induction hardening process, then production costs increase and process time is lost
Solution Approach 1:
The patent applies beforehand cushioning by incorporating reinforcement elements that act as protective measures against mechanical damage. The rigidening ribs, reinforcement rings, and reinforcement brackets are installed in advance to cushion and distribute mechanical stresses during low-frequency operation, preventing catastrophic failures and ensuring continuous reliable operation without interruption to production schedules.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The tool significantly extends the lifespan of inductors and consoles, achieving hardened layers up to 60 mm depth with improved quality and reliability, reducing production costs and enhancing the induction hardening process efficiency.
Implementation Method 1
a cooling system, comprising: a cooling channel provided in the interior of at least one coil of the at least one inductor and on at least one console
Implementation Method 2
a reservoir arranged to store cooling water, said reservoir connected to the mentioned cooling channels and the sprinkler, a pump for allowing flow of the cooling water through the cooling channels and the sprinkler
Implementation Method 3
a tool for induction hardening of cylinders with low frequencies... at least one inductor with a space arranged to receive a cylinder for induction hardening and with at least one coil
Implementation Method 4
During induction hardening of steel, the workpiece is heated in an induction loop
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
The present invention belongs to the field of metallurgy, more precisely to the field of devices for hardening. The invention relates to a tool for induction hardening of cylinders with low frequencies, comprising a cooling system designed to prevent deformation of the inductor material due to high inner forces caused by low frequencies of powering voltage. The tool (1) comprises a high-frequency inductor (4) and a low-frequency inductor (2) with a space arranged to receive the cylinder for hardening, wherein each inductor is provided with its own console (3, 5), a transformer for powering the inductors (2, 4) connectable to the consoles (3, 5), electronic circuit for controlling and electric circuit for powering the tool, as well as the cooling system. The latter comprises a cooling channel (23) on at least one coil of each inductor (2, 4) and/or a channel (31b, 32a, 33a) on each console (3, 5), a reservoir with cooling water connected to said cooling channels, a pump for allowing flow of the cooling fluid along the channels, a temperature sensor (28) for measuring cylinder temperature, and a sensor for measuring flow of cooling liquid. The cooling system further comprises a sprinkler (6) for cooling the cylinder, said sprinkler installed below the inductors (2, 4).