DESC:FORM 2

THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENT RULES, 2003

COMPLETE SPECIFICATION
(See Section 10 and Rule 13)

Title of invention:
PROGRESSIVE INDUCTION HARDENING COIL

Applicant:
BEML Limited
A company Incorporated in India under the Companies Act, 1956
Having address:
BEML Soudha, 23/1, 4th Main,
Sampangirama Nagar, Bengaluru - 560 027,
Karnataka, India

The following specification particularly describes the invention and the manner in which it is to be performed
CROSS-REFERENCE TO RELATED APPLICATION AND PRIORITY
[001] The present application claims priority from Indian Patent application no. (202041001866) filed on 15th January, 2020.
TECHNICAL FIELD
[002] The present subject matter described herein, in general, relates to an induction hardening coil and more specifically relates to progressive induction hardening of V-groove profile.
BACKGROUND
[003] Generally, heavy industries include applications like mining, powertrain, suspension, engine components, military, construction equipment and stampings. In above mentioned applications, the components are highly stressed and therefore subjected to induction hardening in order to increase mechanical properties, dynamic strength and wear resistance. Generally, induction hardening is a type of surface hardening followed by quenching. Quenching process is basically performed for rapid cooling of components in water or polymer etc.
[004] Conventionally, for complex profile of components, single shot hardening is used with high power (50KW) followed by water quenching wherein the component is heated all over and quenched in water jet with quench pressure of 2.5 kg/cm2 wherein possibilities of heat affected zone is more. However, in some components all over heating is not required. Further, single shot hardening leads to uneven hardness, cracks, uneven hardening pattern and larger heat affected zone. Also, the single shot hardening process requires skilled person for truing the component that may lead to operator fatigue and lowers the production. Hence, there is need to develop a device or a method which heats the component locally only in required area with less heat affected zone which solves the above-mentioned problems.

OBJECT OF THE INVENTION
[005] Main object of the present invention to provide a progressive induction hardening for V-groove profile components.
[006] Another object of the present invention to provide localized heating of a component on required area.
[007] Another object of the present invention to provide a single turn closed loop rectangular hollow copper coil for progressive induction hardening.
[008] Yet another object of the present invention to provide uniform heating over required area of a component.
[009] Yet another object of the present invention to provide angular quenching to a component.
[0010] Yet another object of the present invention to develop a simple and easy to mount design of progressive induction hardening coil to provide easy repairing and to eliminate an arc in the said coil.
[0011] Yet another object of the present invention is to prevent overheating of a component.
[0012] Yet another object of the present invention is to eliminate soft patches on a component.
[0013] Yet another object of the present invention is to eliminate cracks and uneven hardening pattern on a component.
[0014] Yet another object of the present invention is to eliminate operator fatigue and increase productivity.
[0015] Yet another object of the present invention is to minimize heat affected zone.

SUMMARY
[0016] Before the present system and method are described, it is to be understood that this application is not limited to the particular machine or an apparatus, and methodologies described, as there can be multiple possible embodiments that are not expressly illustrated in the present disclosures. It is also to be understood that the terminology used in the description is for the purpose of describing the particular versions or embodiments only, and is not intended to limit the scope of the present application. This summary is provided to introduce aspects related to a system for induction hardening of V-groove profile components, and the aspects are further elaborated below in the detailed description. This summary is not intended to identify essential features of the proposed subject matter nor is it intended for use in determining or limiting the scope of the proposed subject matter.
[0017] The present invention discloses a device for progressive induction hardening of V-groove profile components. The device for progressive induction hardening of V-groove profile components may comprise of at least one single turn closed loop copper coil configured with a cooling provision and at least one quenching jacket with provision for angular quenching of the component. The profile of the progressive induction hardening coil and the quenching jacket may configured to match the profile of the component. By using the said device, the component may be heated at one end and progressively heated to another end. This type of hardening may results in local heating of the component in required area and after heating, the component may be quenched with water or a polymer. The progressive induction hardening coil and the quenching jacket may be configured with separate insulation to eliminate arc in the coil during process. Further, the present invention may eliminate overheating, development of soft patches, cracks, heat affected zone and uneven hardening pattern of the components.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The foregoing summary, as well as the following detailed description of embodiments, is better understood when read in conjunction with the appended drawing. For the purpose of illustrating the disclosure, there is shown in the present document example constructions of the disclosure, however, the disclosure is not limited to the specific methods and apparatus disclosed in the document and the drawing:
[0019] The detailed description is described with reference to the accompanying figure. In the figure, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the drawing to refer like features and components.
[0020] Figure 1 illustrates a device for progressive induction hardening of a V-groove profile, in accordance with one embodiment of the present subject matter.
[0021] Figure 2 illustrates a single turn closed loop rectangular hollow copper coil for induction heating, in accordance with one embodiment of the present subject matter.
[0022] Figure 3 illustrates a quenching box configured to quench a V-groove profile during induction heating, in accordance with one embodiment of the present subject matter.
[0023] Figure 4 illustrates an isometric view of a single turn closed loop rectangular hollow copper coil with mounting attachments, in accordance with one embodiment of the present subject matter.
[0024] The figure depicts various embodiments of the present disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following discussion that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
DETAILED DESCRIPTION
[0025] Some embodiments of this disclosure, illustrating all its features, will now be discussed in detail. The words "comprising", “having”, and "including," and other forms thereof, are intended to be equivalent in meaning and be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items. Although any systems and methods similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present disclosure, the exemplary, systems and methods are now described. The disclosed embodiments are merely exemplary of the disclosure, which may be embodied in various forms.
[0026] Various modifications to the embodiment will be readily apparent to those skilled in the art and the generic principles herein may be applied to other embodiments. However, one of ordinary skill in the art will readily recognize that the present disclosure is not intended to be limited to the embodiments illustrated, but is to be accorded the widest scope consistent with the principles and features described herein.
[0027] For induction hardening of components, a copper tube induces heat on a component to a required temperature to heat the component followed by quenching of the components. Heating of the copper tube is achieved by supplying an alternating current through the copper tube. For quenching of the components, various types of quenching techniques may be adopted, for example spray quenching. In progressive induction hardening of components, the copper tube generates magnetic field which results in heating of the component profile. As a result, the component is heated only at required area, hence, the component is locally heated.
[0028] Referring to figures 1 to 4, the device (100) may be used for progressive induction hardening of V-groove profile components. The device (100) comprises a copper tube (102) that may act as an induction hardening coil and a quench box (106).
[0029] The induction hardening coil (102) may be a single turn closed loop rectangular hollow copper coil. In an embodiment, the copper tube (102) may have 99% purity and a thickness of 2mm. The copper tube (102) may be configured with at least one inlet and at least one outlet. The said inlet and outlet may be provided for water-cooling of the copper tube (102). In one of the embodiments, the copper tube (102) is operated with an operating power of 25 KW and a frequency of 10 KHz and the component may be provided a circumferential movement of 5mm/sec. Further, the induction hardening coil (102) is configured to match the profile of the component. The induction hardening coil (102) is provided with mounting attachments (104). In an embodiment, the size and shape of the mounting attachments (104) may vary based on size of the copper tube (102).
[0030] Further, the device (100) may comprise a quenching jacket (106). The quenching jacket (106) is the quenching box with plurality of holes (302). The quenching jacket (106) may comprise a closed loop rectangular hallow copper coil with a thickness of 2mm and a hole size of 1.8 mm. The quenching jacket (106) is provided with mounting attachment (108). The said coil may configured to match the V-groove profile of the component. Further, the induction hardening coil (102) and a quench box (106) may be insulated to avoid arc in the induction hardening coil (102).
[0031] Accordingly, the present invention discloses a device for induction hardening of V-groove profile components comprising at least one hollow induction coil (102) of conducting material with a predetermined profile configured to match the V-groove profile of the component for localized and uniform heating, wherein the hollow portion of the said coil is configured with cooling provision and at least one quenching jacket (106) configured with plurality of quenching holes (302) for quenching of component after induction heating, wherein said quenching jacket (106) is provided with plurality of water inlet holes. Further, the component of the present invention is heated at one end and progressively heated to another end.
[0032] The progressive induction hardening coil (102) is configured with at least one inlet and at least one outlet for water cooling of the coil. The progressive induction hardening coil (102) is provided to be operated at a power of 25 KW, at frequency of 10 KHz, wherein the power and frequency of operation is configured to vary based on the size of the induction coil and component. The component adapted for circumferential movement of 5 mm/sec, is configured to vary the speed of movement based on the size of the induction coil and component. The quenching jacket (106) adapted to quench at pressure of 2.5Kg/cm² is configured to vary the pressure of quenching based on the size of the induction coil and component. The quenching jacket (106) with a hollow copper coil of 2mm thickness and hole size of 1.8 mm is configured to vary the thickness and hole size based on the size of the induction coil and component. The size and profile of the progressive induction coil and quenching jacket is configured to vary based on the size of the component. The progressive induction hardening coil and quenching jacket are configured to be insulated to avoid arc in the induction hardening coil.
[0033] Exemplary embodiments discussed above may provide certain advantages. Though not required to practice aspects of the disclosure, these advantages may include those provided by the following features.
[0034] Some objects of the present invention enable to develop a simple and easy to mount design of progressive induction hardening coil for V-groove profile components.
[0035] Some objects of the present invention reduce blockage in a coil and quench box for easy cleaning, thereby reducing fatigue of operator.
[0036] Some objects of the present invention reduce damage to a coil in a quenching process, thereby increasing productivity.
[0037] Some objects of the present invention provide better control of material properties of a component.
,CLAIMS:
1. A device (100) for progressive induction hardening of V-groove profile components comprising:
at least one hollow induction coil (102) of conducting material configured to match the V-groove profile of the component for localized and uniform heating, wherein the said hollow induction coil (102) is configured with cooling provision; and
at least one quenching jacket (106) with plurality of holes (302) for quenching of component after induction heating configured with predetermined angular profile.

2. The device (100) for progressive induction hardening of V-groove profile components as claimed in claim 1, wherein the said hollow induction coil (102) is configured to be a copper tube with plurality of concentrators (202) fixed on the copper tube.

3. The device (100) for progressive induction hardening of V-groove profile components as claimed in claim 1, wherein said induction hardening coil (102) is configured with at least one inlet and at least one outlet for water cooling of the coil and wherein the said inlet is insulated to avoid arc in the coil.

4. The device (100) for progressive induction hardening of V-groove profile components as claimed in claim 1, wherein said induction hardening coil (102) is provided to be operated at a power of 25 KW, at frequency of 10 KHz, and wherein the power and frequency of operation is configured to vary based on a size of the coil and component.

5. The device (100) for progressive induction hardening of V-groove profile components as claimed in claim 1, wherein the induction heating coil (102) adapted for circumferential movement of 5 mm/sec, is configured to vary speed of movement based on the size of the induction coil and component.

6. The device (100) for progressive induction hardening of V-groove profile components as claimed in claim 1, wherein the said quenching jacket (106) is a hollow copper quench box with an angle of 60 degree, thickness of 2 mm and hole size of 1.8 mm wherein the angle, thickness and hole size is configured to vary based on the size of the induction coil and component.

7. The device (100) for progressive induction hardening of V-groove profile components as claimed in claim 1, wherein the quenching is configured to be an angular quenching with water or polymer as a fluid for quenching.

8. The device (100) for progressive induction hardening of V-groove profile components as claimed in claim 1, wherein said quench box of the quenching jacket (106) is configured with an insulation to avoid arc in the coil.

9. The device (100) for progressive induction hardening of V-groove profile components as claimed in claim 1, wherein the size and profile of the induction hardening coil (102) and quenching jacket (106) is configured to vary based on the size of the component.