Crankshaft Quenching Machine

Crankshaft Quenching MachineConfigurationThis equipment mainly consists of crankshaft quenching machine,Website:, IGBT MF power supply, quenching liquid circulation cooling system, purified water cooling circulation system (including low-pressure cooling system 0.1-0.2Mpa, 0.6-0.8Mpa high-pressure cooling system), electric control system, chiller and the like. The equipment can do  journal quenching or fillet hardening for all kinds of four-cylinder and six-cylinder crankshafts with a length of 500-1500mm.Automatic monitoring protection of the temperature, pressure and flow rate of quenching liquid and cooling water. The control system has the function of failure protection, indication and alarming.The power chuck, tailstock and transformer lifting driving mechanism of the hardening machine are pneumatic; the loadding and unloading mechanism adopts a reciprocating type double-position trolley driven by a motor to synchronously drive; and the lifting force for parts is from an air cylinder.Machine head and machine tail: the machine head and machine tail are tightly clamped by the power chuck of a rotation air cylinder and driven by a servo motor to rotate, at the same time, the tail stock position can be electrically adjusted to fit for the quenching of the crankshaft with different lengths.Crankshaft moving system: Servo motor and ball screw are adopted to drive the crankshaft to transversely move; and the guide rail adopts a rectangular linear guide rail.Load feeding: The power for load ascending and descending is from the air cylinder.The machine is equipped with 6~15 sets of load systems (including quenching transformer, capacitor, inductor and the like); each set of load system can work independently by sequentially switching; the distance between transformers can be manually adjusted by 0-100mm.The technological parameters of load working can be set independently.The holding of the crankshaft adopts a center hole and an end surface for positioning, the machine head and the tailstock adopt an pneumatic self-centering power chuck, the holding of the crankshaft is automatically completed, the tailstock can freely expand and contract according to the extension amount of the crankshaft, and the holding length is electrically adjusted by a screw.The control system of the machine adopts Mitsubishi PLC, data acquisition and data processing unit, touch screen and the like, and the actions of the machine have the interlocking protection, and the process parameters of the equipment (including voltage, current, heating time, cooling time, power, frequency, spray flew and the like) can be displayed and set on the touch screen, and the Siemens 840D systems can be selected as the electric control system.Besides the functions of overpressure protection, over-current protection, phase failure protection and water pressure failure protection, the power supply even has the functions of voltage-limit protection, current-limit protection, minimum protection, over-high inlet voltage protection, over-high starting current protection and water temperature protection. And it has interlocking protection with the matched machine, the power supply can’t start until the machine is well prepared.The process parameters monitor can monitor the heating parameters of each heating position and record.Advanced technology adopted by HKCR Type Crankshaft Quenching MachineSolid no-contact switching technique: the switching between work stations adopts solid switch.Power pulse distribution technique: it can ensure the uniformity of hardening layers at the circumferential directions of any shaft journal.Tailstock freely floating technique: it can ensure that the crankshaft extends freely when heated and shortens freely when cooled, to reduce the deformation of the crankshaft.Thin type quenching transformer: 5-15 thin type quenching transformers with volume of 750Kva and thickness of 55-75mm can be simultaneously suspended on the hardening machine.Independent suspension technique: each quenching transformer adopts independent suspension, the distance between any adjacent transformers can be adjusted by a manual screw to fit for the quenching of the crankshaft of different press openings to ensure the flexibility of the machine.Suspension balancing technique: the transformer suspension adopts a spring type adjustable balance to ensure that the induction coils can be well tracked and the crankshaft quenching deformation can be reduced.Monitoring of the working state and process parameters of the machine: 10 inch large screen color LCD touch screen is adopted to monitor and display the working states of the machine and the process parameters of heating and quenching cooling(including heating voltage, current, working frequency, heating/cooling time, heating energy, pressure, flow, cooling water/quenching liquid and the like).More than 90% of the parts and devices of the machine and the power supply are imported famous-brands.The machine adopts a modular structure, so compared with imported equipment, it’s simple to install and convenient to maintain, and at the same time, the occupied area is greatly reduced.Technical characteristics of quenching machineIt can do fillet hardening and shaft journal hardening on all kinds of crankshafts, and it has both the automatic and the manual cycle operation modes.Series equipment can feed 1-6 inductors at one time, and heat 1-3 inductors while spraying and cooling at the same time. The heating and cooling technical parameters of each inductor can be separately adjusted.The loading, unloading, workpiece positioning and clamping and the processing process are automatically controlled by the machine.The machine bed is integrally welded,　thus it has good rigidity, stability and shock resistance.The machine is equipped with overhaul adjusting channel,which is convenient for changing quenching fixture and inductor, and easy for cleaning quenching tank and changing quenching liquid.The touch screen can display and monitor the whole process, technical parameters, fault diagnosis and warning lamp.The machine head adopts pneumatic self-centering chuck, which can automatically clamp the workpiece. The tailstock can move freely on guide rail to fit for different workpiece lengths.Crankshaft positioning mode: the crankshaft center is positioned by machine head and tailstock center, and the crankshaft left-right position is determined by the shaft end surface.The spindle rotation drive of the machine adopts AC servo drive, which can rotate in any angle and position there.The dragging plate left-right moving is achieved by AC servo motor driving the ball screw, screw and guide are both imported; the transmission mechanism has good positioning precision, abrasion resistance, rigidity, stability in low speed and vibration resistance. The moving speed of the dragging plate is in the range of 0-100mm/S; the slipway guide is equipped with a protective cover.The moving up and down of the inductor is driven by SMC self-locking cylinder, and it is equipped with buffer device, which has automatic protection function of power and gas shutdown. The inductor is equipped with fast/slow speed control mechanism, which ensures the inductor to precisely reach the quenching area in the shortest period of time without knocking.The special quenching transformer of the thin type crankshaft is connected with the water pipeline, circuit and gas circuit of the inductor by fast-changing devices; each quenching transformer is hung independently, the distance between any adjacent transformers can be adjusted by a manual screw to fit for the crankshaft quenching of different press openings to ensure the flexibility of the machine, the transformer suspension adopts a spring type adjustable balance to ensure that the induction coils can be well tracked and the crankshaft hardening deformation can be reduced. All the cooling water pipes, quenching water pipes of transformer and inductor are imported from Sweden, and the quick joints are all originally imported.The full-film capacitor produced by American GE company has a small volume and high stability, and the capacitor can be adjusted in shortcut method.The power supply adopts international advanced IGBT transistor, which is controlled by DSP, the power supply has the outstanding performance of high efficiency, low pmalfunction , and high startup successful ratio. Meanwhile, it owns the complete protective function and disgnosis-alarm function. The power supply is provided with various power channels that can be switched automatically, which has power pulse distribution function in connecting rod shaft diameter quenching to ensure the uniformity of the quenching layers of the shaft journal at the circumferential directions. All safety indexes of medium-frequency power supply can meet the national standard, the protection level is IP65; the medium-frequency power supply is fully closed, and it is equipped with overhaul illumination and socket.The cooling water cycle system adopts soft water cycle cooling; the heating power supply adopts low pressure cooling, the loading system includes quenching transformer, the inductor adopts high pressure cooling, each cooling branch is equipped with temperature, pressure and flow monitoring and protecting device.The quenching liquid cycle system adopts PAG water-soluble medium, the quenching branch is equipped with SMC piston solenoid valve, and temperature, pressure and flow monitoring and protecting device.Both the cooling water and quenching liquid circulation systems adopt high efficient stainless heat exchanger and chiller unit (or circulation cooling water in customer’s factory) to exchange heat, it has strong cooling performance and high precision of temperature control, which can ensure long-term reliable service of the equipment and stable quenching quality of the crankshaft. The chiller unit is equipped with temperature and pressure monitoring-displaying device, which can sutomatically adjust according to the temperature of the cooling water and quenching liquid.The complete equipment includes machinery, power supply and heating load system, cooling water and quenching liquid circulation system, and chiller unit, which can be directly installed on the workshop ground, and there is no need for customers to prepare pond, cooling tower or other auxiliary facilities.The complete equipment is finished as a turn-key project.

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