DESC:FIELD OF THE INVENTION
[001] The present subject matter relates to hardening operation and particularly, not exclusively, relates to induction hardening of metal components.
BACKGROUND OF THE INVENTION
[002] Hardening is a metallurgical heat treatment process that increases a hardness of a metallic surface. Further, hardening can be performed by various techniques, such as work hardening, precipitation hardening, induction hardening, or the like. Typically, induction hardening is a form of heat treatment in which a metal part is heated by induction heating and then quenched. This process utilizes the principle of electromagnetic induction to produce heat inside the surface layer of a work-piece. Further, the quenching operation may be understood as rapidly cooling the heated metal component. During induction hardening, the quenched metal undergoes a martensitic transformation, thereby increasing the hardness and brittleness of the part. Generally induction hardening is used where portions of metal component are to be selectively hardened without affecting the properties of the component as a whole.
[003] Various techniques are known for performing induction hardening of the metal components. For example, US6555800B1 relates to a process and an apparatus for the induction hardening of crankshafts. This conventional process elaborate the equipment details such as use mechanical worm drive to pivot and rotate the crankshaft about its axis using electric energy, a carriage which can be adjusted along a guideway disposed perpendicular to the central axis of the crankshaft, a gauge block, adapted to adjust the length of the adjusting device, a latching provided for various dimensions for setting the central axis of the connecting-rod pin to be hardened of the crankshaft as the axis for the rotation of the crankshaft, a fork-like receiving and adjusting element, which receives one of the connecting-rod pins, and provides for aligning the crankshaft before hardening, etc.
[004] Conventionally, induction hardening of the metal components, such as crankshafts, is performed on a machine platform on which the component can be placed. Further, the machine platform being used is made of fabricated and cast base with mounting of sub-assemblies. Further, induction coils or simply inductors are used to induce electromagnetic inductions. In one example, the inductor is mounted on a pantograph mechanism that provides motion to the inductor to move the inductor with respect to the component. Generally, an induction hardening system includes multiple pantographs to mount different inductors of various energy ratings. Moreover, pantographs are actuated using pneumatic actuators and guided by fixed guides in the system to perform induction hardening. Further, based on the requirements, such as the amount of heat to induce in the component, inductor is selected. However, such arrangement has various limitations such as high infrastructure cost, because the system employs individual pantograph mechanisms to operate the inductors. Moreover, use of multiple pantograph mechanisms in a single system also adds to the complexity of the induction hardening system. In order to reduce the complexity of the system, lesser number of inductors may be used. However, reduction in the number of inductors reduces flexibility to harden different components.
[005] Therefore, there remains a need for a system for the induction hardening to achieve higher accuracy, economical manufacturing and technological advancement.
OBJECTS OF THE INVENTION
[006] An object of the is to build fexible and cost efficicent induction hardening system.
[007] Another object of the invention is to increase accuracy and better control over the induction hardening process.
[008] Another object of the invention is to increase flexibility of moving the inductor coil to a desired position.
[009] Yet another object of the invention is to reduce the consumption of space to set up the induction hardening machine.
SUMMARY OF THE INVENTION
[0010] This summary is provided to introduce concepts related to an induction hardening system for hardening metal components, and these concepts are further described below in the detailed description. This summary is not intended to identify essential features of the claimed subject matter nor it is intended for use in determining or limiting the scope of the claimed subject matter.

[0011] The present subject matter relates to a system and a method of performing induction hardening on at least a portion of a component. The system may include a platform to hold the component for induction hardening. The platform includes a headstock and a tailstock to mount the component thereon and the component moves along with headstock and tailstock parallel with respect to the base of the system. The system also includes an induction coil mounting station that may house a plurality of inductor coils where each inductor coil heats upto their predetermined temperature. Further, the system includes an automatic tool changer to selective mount and dismount one of the plurality of inductor coil based on the predetermined temperature to be achieved.
[0012] According to an implement of the present subject matter, automatic coil change and servo movements of the inductor coil make the invention more flexible and accurate for the manufacturing automobile components using induction hardening.
BRIEF DESCRIPTION OF DRAWINGS
[0013] Fig. 1a-1b shows an induction hardening system, in accordance with one implementation of the present subject matter.
[0014] Fig.2 shows an inductor parking station, in accordance with one implementation of the present subject matter.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The description that follows and the embodiments described therein, are provided by way of illustration of an example, or examples, of particular embodiments of the principles of various aspects of the present subject matter. These examples are provided for the purposes of explanation, and not of limitation, of those principles and of the invention in its various aspects. In the description, similar parts are marked throughout the specification and the drawings with the same respective reference numerals. The drawings are not necessarily to scale and in some instances proportions may have been exaggerated in order more clearly to depict certain features.
[0016] According to the present subject matter, a single tool changer is used to mount and operate multiple inductor coils in the induction hardening system. As a result, the induction hardening system does not require individual tool changer to mount inductor coils. Moreover, absense of individual tool changers does away a need of complex circuitary to operate individual tool changer. As a result, the induction hardening system is compact in size and efficient in operation. Moreover, movement of the inductor coils and the component are based on the coded instructions as opposed to conventional control system. Therefore, the inductor coils based on the present subject matter has more freedom of movement than in the conventional induction hardening system.
[0017] Fig. 1a-1b illustrates an induction hardening system 100, in accordance with one implementation of the present subject matter. Further, Fig. 1a illustrates a side view of the induction hardenning system 100, while fig. 1b illustrates a front view of the induction hardening system 100. The induction hardening system 100 can be used to perform induction hardening on component 2 that can be a piston, crankshaft, or the like, used in automobile, marine, locomotives or in any relevant sector. In the illustrated example, the induction hardening apparatus can be used to harden a crankshaft.
[0018] In one example and with respect to Fig. 2, the induction hardening system 100 also includes a hydraulic clamp or anautomatic tool changer 17 to detatchably mount an inductor coil 14 thereon. In one example, the automatic tool changer 17 can move the inductor coil 14 along a vertical axis 13 (as shown in Fig. 1a). The induction hardening system 100 also includes an induction mounting station 16 to keep multiple inductor coils of different energy ratings. The energy rating may be understood in terms of a predetermined temperature upto which the inductor coil can heat the component 2. Further, the automatic tool changer 17 may select the inductor coil based on various parameters, such as the amount of heat to be induced in the component 2.
[0019] Referring back to Fig. 1a-1b, the induction hardening system 100 may include a transformer (not shown in Fig.) that provide alternative current to the inductor coil 14. In one example, the transformer can be a flat type transformer. Further, the transformer can be installed in a vertical column of the induction hardening system 100 above the hydraulic clamp. Furthermore, the transformer can provide alternative current of different magnitudes and different frequencies. In another example, the transformer can provide alternative current of fixed current and frequency. The induction hardening system 100 may include a cover 4 that covers the component 2 from outside environment while the induction hardening operation is taking place. Further, in order to provide view to the component 2 to the operator during the induction hardening process, a window may be provided in the cover 4.
[0020] According an aspect, the induction hardening system 100 includes a platform 11 on which the component 2 can be placed. Further, the platform 11 may include sub assemblies to mount the component 2. In one example, the component 2 includes a headstock 8 and a tailstock 9 to mount the component 2 on the platform 11. Further, the headstock 8 may be provided with a servo motor to rotate the component 2. In another example, the headstock 8 and the tailstock 9 can move with component 2 along X and Y axis parallel to the base of the induction hardening system 100. In other words, the component 2 can be moved between left and right or out of the page and into the page as shown in Fig. 1b parallel to the base of the induction hardening system 100.
[0021] The induction hardening system 100 also includes a controller (not shown) for controlling the functioning of the induction hardening system 100. In one example, the controller may control the transformer to provide energy to the inductor coil 14. Further, the controller may also control the automatic tool changer 17 to select and actuate the inductor coil 14. In addition, the controller may also actuate the servo motors of the headstock 8 to impart motion to the component 2. In one example, the controller can be a CNC based microprocessor, or the like.
[0022] The operation of the induction hardening system 100 will now be described. For the foregoing embodiment, it is assumed that the component 2 is a crankshaft. Initially, the component 2 is mounted on the platform 11 and secured on the platform 11 between the headstock 8 and the tailstock 9. Once mounted, the controller is provided with the instructions to conduct induction hardening operation and the parameters associated thereto. Therafter, the operator may trigger the controller to begin the induction hardening operation. The controller then, based on the received instructions, selects the inductor coil 14 from amongst the inductors coils parked inside the parking station 16. For example, the controller actuates the automatic tool changer 17 to select the required inductor coil from the parking station and mount the selected indicator coil 14 thereon. Once the selected inductor coil 14 is mounted, the controller actuates the automatic tool changer 17 to move the inductor 14 near to the component 2. Thereafter, the controller operates the headstock 8 to impart motion to the component 2. In one example, the controller actuates the servo motor of the headstock 8 to rotate the component 2 by a predefined degree (as specified in the instruction fed into the controller). In addition, platform 11 moves headstock 8, tailstock 9 and component 2 simultaneously along X-axis to position a portion of the component 2 where the inductor coil 14 can perform induction hardening. Once in position, the inductor coil 14 is moved along the central axis 13 and the inductor coil 14 is also positioned with respect to the portion of the component 2. Thereafter, the controller actuates the transformer to apply alternating current to the inductor coil 14.
[0023] As the inductor coil 14 is provided with alternating current, the inductor coil 14 induces an alternative magnetic field into the portion of the component 2 causing the formation of electric field which heats up the portion of the component 2. Further, the current is fed to the inductor coil 14 till the portion of the component 2 is heated upto a predetermined temperature. Once the predetermined temperature is achieved, the controller actuates the transformer to stop providing the current to the inductor coil 14. Thereafter, the component 2 may be dismounted from the platform 11 and discharged to another station where the component 2 is quenched. Alternatively, the component 2 can be quenched by a quenching mechanism (not shown in Fig.) within the induction hardening system 100.
[0024] In another example, there may be a case where a second component or other portion of the component 2 may be hardened by induction hardening. However, the predetermined temperature upto which the portion is to be achieved by the induction hardening process may be different than the previous component or portion of the component 2. In such case, the controller is provided with new set of instructions. In one example, the controller actuates the automatic tool changer 17 to dismount the previously mounted inductor coil 14 and park the dismounted inductor coil 14 in the parking station 16. Thereafter, the automatic tool changer 17 selects an inductor coil from the parking station best suited to perform the induction hardening on the second component or portion of earlier component 2. Once selected, the controller performs a series of operation based on the provided instructions for the second component or portion of earlier component. Thus, single automatic tool changer 17 may be used to mount different inductor coils 14 to achieve different temperatures for the purpose of hardening.
TECHNICAL ADVANCEMENT AND ECONOMIC SIGNIFICANCE
[0025] The present invention reduces the required floor space as compared to convention induction hardenining system.
[0026] The present invention provides a induction hardenining system which ensures increase in flexibility of moving the inductor coil to desired position.
[0027] The present invention increases accuracy and control over the induction hardening process.
[0028] The above description of exemplary embodiments of the present subject matter is not intended to be exhaustive or to limit the embodiments of the invention to the precise forms disclosed above. Although specific embodiments and examples are described herein for illustrative purposes and to allow others skilled in the art to comprehend their teachings, various equivalent modifications may be made without departing from the spirit and scope of the disclosure, as will be recognized by those skilled in the relevant art.
,CLAIMS:I/ WE CLAIM:
1. An induction hardening system (100) comprising:
a platform (11) to mount a component (2) thereon;
an induction coil mounting station (16) to store a purality of the inductor coil (14); and
a tool changer (17) to selectively mount one of the plurality of inductor coil based on a predefined parameter.
2. The induction hardening system (100) as claimed in 1 further comprising a transformer to energize the inductor coil mounted on the tool changer (17).
3. The induction hardenning system (100) as claimed in 1, wherein the platform (11) further comprises a headstock (8) and a tailstock (9), and wherein the headstock (8) and tailstock (9) is mounted with component (2).
4. The induction hardenning system (100) as claimed in 3, wherein the headstock (8) and tailstock (9) is to move the component (2) along a surface of the platform (11) to position a portion of the component (2) with respect to the inductor coil (14) to perform the induction hardening thereon.
5. The induction hardening system (100) as claimed in claim 3, wherein the headstock further comprises a servo motor to impart rotational motion to the component (2).
6. The induction hardening system (100) as claimed in claim 2, wherein the transformer is to provide alternating current of different frequency and magnitude.
7. The induction hardening system (100) as claimed in claim 2, wherein the transformer is to provide alternating current of predefined frequency and magnitude.
8. The induction hardening system (100) as claimed in claim 1 further comprising a controller operably coupled to the platform (11) and the tool changer (17) to control the induction hardening operation of the component (2).
9. The induction hardening system (100) as claimed in claim 8, wherein the controller is a CNC based microprocessor.
10. A method of performing induction hardening on at least a portion of a component (2), the method comprising:
placing the component (2) on a platform (11);
recieving instructions from an operator, wherein the instruction includes a predetermined temperature upto which the component (2) is to be heated;
selecting one of a plurality of inductor coils (14) based on the predetermined temperature; and
performing induction hardening on the at least the portion of the component (2) using the selected inductor coil.
11. The method as claimed in claim 10 further comprising:
recieving a second instruction from the operator to perform induction harderning on a second componennt;
dismounting and placing the currently mounted inductor coil;
selecting and mounting another inductor coil based on a second predetermined temperature; and
performing the induction hardening using the next selected inductor coil.
Dated this 27th Day of September 2018