**EFD Induction Heating Power Supply**
The latest trend in induction heating power supplies is the use of fully digital control systems, with IGBT inverter modules replacing traditional components. These modules are designed for high durability and can operate reliably even in harsh environments. The power output circuit can be configured with either series or parallel compensation, depending on the application requirements. To enhance efficiency and energy savings, especially in industrial settings, a diode full-regulation circuit is used in the primary rectification stage. This ensures a stable power factor above 95%, significantly contributing to energy conservation.
The matching box is carefully selected based on specific applications, ensuring that the appropriate transformer and capacitor are used to achieve the desired processing frequency and maximize power output at that frequency. Unlike conventional quenching machines, which only check the gap between the inductor and workpiece before heating, the EFD system continuously grounds both the workpiece and sensors during the heating process, improving safety and performance.
Real-time monitoring of output power, frequency, voltage, and current is implemented, with data displayed on a computer screen. If any parameter exceeds the set limits, the system triggers an alarm, making fault detection straightforward. It's crucial to match the power supply with the specific application, as using a general-purpose unit in a specialized setting can lead to inefficiency and reduced output. For example, a 300 kW power supply might only deliver 100–150 kW in such cases.
**EFD Induction Hardening Machine**
EFD’s crankshaft quenching machine is capable of both rounded and non-rounded quenching, allowing for the treatment of connecting rod journals, crankshaft journals, flanges, and oil seal ends. It also supports residual heat tempering and induction tempering. The induction coil has a long service life, typically over 50,000 cycles, with minimal maintenance required. EFD technology now reaches up to 100,000 cycles. The deformation during heat treatment is strictly controlled, usually below 0.2 mm. Different countries have varying power and frequency requirements, so EFD offers customized solutions. The machine supports robot loading/unloading, trolley-based loading, and even stepping machines for high-volume production. It can handle crankshafts up to 10 meters in length.
**Camshaft Quenching**
While many still use scanning quenching, EFD employs profile quenching to ensure uniform hardness distribution. This method avoids issues like cracking or peeling that occur with circular scanning. When camshafts are closely spaced, EFD’s three-camshaft simultaneous quenching system prevents unwanted tempering. The automatic machine uses robots for loading, and options like double- or four-station systems are available to improve efficiency.
**Profiled Quenching of Pinion**
EFD has patented a dual-frequency system for this process, combining preheating and quenching in one operation. Computer simulations help optimize power and frequency parameters, ensuring results close to simulation predictions. This reduces waste and improves accuracy.
**Large Ring Gear and Raceway Quenching**
For ring gears with a module greater than 6, EFD’s single-tooth quenching system automatically detects each tooth’s position. The machine features patented no-soft-band technology, and has successfully processed bearings up to 8 meters in diameter. A cantilever design saves space, while tilting machines increase efficiency for raceway quenching. Double-head gantry systems allow deeper hardening with less risk of cracks.
**Ball Screw Quenching and Tempering**
EFD’s fully automatic ball screw machine can quench both slotted and round bars. After hardening, it performs hard milling and offers simultaneous quenching and tempering with automatic loading and unloading.
**Guide Rail Quenching and Tempering**
With growing demand for guide rail quenching, EFD uses a three-station system for pre-heating, quenching, and tempering. Fully automated loading and unloading ensure precision and reduce deformation.
**Car Steering Gear Rack Quenching and Tempering**
EFD offers both induction and conductive quenching methods. While induction is more costly, it provides better quality. Conductive quenching is used for teeth and back surfaces, with induction tempering applied afterward. EFD’s machines can process multiple racks simultaneously, optimizing efficiency.
**Constant Velocity Joint Quenching and Tempering**
Fully automated, the system includes functions like automatic loading, cleaning, marking, and eddy current testing. The entire cycle takes 20–30 seconds per piece, with integration of tempering into the hardening process.
**Second- and Third-Generation Wheel Bearings**
EFD’s fully automatic unit processes inner and outer rings simultaneously, achieving a cycle time of 12 seconds per piece. It handles quenching, tempering, and all necessary steps in one machine.
**Synchronizer Toothed Sleeve Induction Heating Quenching and Tempering**
EFD heats and quenches three sleeves at once, using infrared sensors for temperature control. The conveyor belt system ensures smooth, automated handling throughout the process.
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