Relying on the specialized techinal team, professional producing technology, ZM can design and produce kinds of customized induction heaters according to User’s work-piece requests. Such as Gear, Gear box, coupling and so on
Feature
* Static Var Compensation, higher heating rate.
* Automatic demagnetization
* Time display switch on temperature mode
* Powerful design for demanding industrial application
* Maximum capacity for both work piece size and heating capacity
* Equipped with handcart ,easy operation.
Specification
Voltage/Current |
380V±10% /92A |
Power Rating |
35.00KVA |
Frequency |
50/60Hz |
Bore diameter of work piece |
φ200-φ800 |
Max. O.D of work piece |
1400mm |
Max. width of Work Piece |
800mm |
Max. weight of bearing / Other parts |
600Kg/450Kg |
Max. temperature (approx) |
240 °C |
Mass Heater body(Incl. Yokes) |
300Kg |
Figure dimension(mm) |
2000mm*1100*1650mm |
Mass Heater body(Incl. Yokes) |
300Kg |
Mass Heater body(Incl. Yokes) |
300Kg |
Mass Heater body(Incl. Yokes) |
2000Kg |
Accessories
Standard yoke |
Min bore diameter of work piece
(Vertical position) |
1100*130*130 |
Φ185mm |
Successful case:
ZM Technical team designed one heavy-duty induction gear heaters to one Customer in South Aisa for gear and gear ring assembly.
Main characteristics
1.1 Model:ZM-CA7490SH
1.2 Structure:standing,movable case
1.3 Max load:5000Kg
1.4 Max temp. 300℃
1.5 Way of control:time-control/digital display/temperature control
automatic alarm after finishing the heating
Heating accuracy;± 5℃
1.6 Electrial parameter:Voltage two-phase AC380V±10%、50HZ、
Rated capacity: 45KVA、
Rated currency:118A、
(We adopt Self healing capacitor compensation for the heater, the power will be around 45KVA after the compensation, the real power is around 90KVA. 50% of power can be saved by this way.)
2. The applicable size of workpiece, yoke configuration and the operation
2.1 Applicable size of workpiece:
Workpiece size:inner diameter:φ180-φ1800mm;
outer diameter:max.φ2500mm; Height:Max.500mm。
2.2 Yoke configuration:
φ 160mm*1pc (Yoke size: 130*110*600mm)
Heating results for work-piece
- Heating Gears:
- Work piece 1: ID 310mm; OD: 1863MM, the assembly tolerance for the inner hole and Shaft is T6 H7. The tolerance on the T6 is 0.272mm. the lower tolerance is 0.24mm;Upper tolerance on the H7 is 0.052, lower tolerance is 0..
According to below parameter, we get the max. tolerance of interference fit between the shift and gear is 0.272mm
Theoretically, the inner ring will be expanded when the work piece be heated up to 180°C
0.272÷12÷0.000001÷310=73℃(Theoretical heating temperature)
Approx. ambient temperature is 20℃+73℃=93℃
Theoretically, when the gear be heated up to 93℃, the inner ring can expanded 0.272mm,but the real expanded temperature is less 20-30℃ to the theoretical temperature. Meanwhile, in order to avoid the assembly of shift occurring eccentricity, so set the target temperature as150-160℃
Approx heating time: Within 2-3 hours for 4Ton of this gear up to 160℃
- Work piece 2: ID 460mm2; OD: 2363MM, the assembly tolerance for the inner hole and Shaft is T6 H7. The tolerance on the T6 is 0.400mm,the lower tolerance is 0.36mm;Upper tolerance on the H7 is 0.063, lower tolerance is 0..
According to below parameter, we get the max. tolerance of interference fit between the shift and gear is 0.4mm.
Theoretically, the inner ring will be expanded when the work piece be heated up to 180°C
0.4÷12÷0.000001÷460=72℃(Theoretical heating temperature)
Approx. ambient temperature is 20℃+72℃=92℃
Theoretically, when the gear be heated up to 93℃, the inner ring can expanded 0.40mm,but the real expanded temperature is less 20-30℃ to the theoretical temperature. Meanwhile, in order to avoid the assembly of shift occurring eccentricity, so set the target temperature as150-160℃
Approx heating time: approx. 3 hours for 4Ton of this gear up to 160℃
- Heating Gear ring
- Work piece 1:The max. interference fit is 1.75mm for the gear whose I.D. is 1500mm
Theoretically, the inner ring will be expanded when the work piece be heated up to 180°C
1.75÷12÷0.000001÷1500=97℃(Theoretical heating temperature)
Approx. ambient temperature is 20℃+97℃=117℃
Theoretically, when the gear be heated up to 117℃, the inner ring can expanded 1.75 mm,but the real expanded temperature is less 20-30℃ to the theoretical temperature. Meanwhile, in order to avoid the assembly of shift occurring eccentricity, so set the target temperature as150-160℃
Approx heating time: approx.2-3 hours this gear ring up to 160℃
- Work piece 2:The max. interference fit is 2.15mm for the gear whose I.D. is 1800mm
Theoretically, the inner ring will be expanded when the work piece be heated up to 180°C
2.15÷12÷0.000001÷1800=99.5℃(Theoretical heating temperature)
Approx. ambient temperature is 20℃+99.5℃=119.5℃
Theoretically, when the gear be heated up to 119.5℃, the inner ring can expanded 2.15 mm,but the real expanded temperature is less 20-30℃ to the theoretical temperature. Meanwhile, in order to avoid the assembly of shift occurring eccentricity, so set the target temperature as150-160℃
Approx heating time: approx. 3-4 hours this gear ring up to 160℃