This small work place was constructed for the hardening of rocker arms for aircraft and motor sport engines. The zone to be hardened is approximately 10mm x 10mm.

The single components of iew have been integrated locally on a worktable supplied by the customer. The small hardening unit consists of a PLC sequence control (menu guidance in German and English) for the power control of the induction system, the activation of a solenoid valve for the emulsion shower and an infrared pyrometer for the temperature measurement. A drip pan for the emulsion liquid has also been integrated in the working table which is also equipped with a temperature sensor and connection to a cooling system to ensure a constant emulsion temperature.

As the weekly number of hardness components was only about 300pcs but the need to integrate the hardening process into the in-house manufacturing process was given, the more cost effective solution where the induction hardening unit was integrated into an already available worktable at the customer was chosen.

This small workplace was designed for the hardening of roller bars in the textile industry.

Since the customer is also an engineering company, they could make the periphery in form of a cooling bath and workpiece fixture by themselves. During the hardening process, the bar is placed in a fixture and is heated at one of the two front ends. Upon reaching the desired temperature, this front end is quenched and hardened by an emulsion shower. Thereafter, the bar is manually rotated 180 degrees, and the hardening process takes place again on the second front end.

Of course, the hardening unit IHU110 is equipped with an infrared pyrometer and a PLC sequence control (menu guidance in German and English). Additionally it is equipped with two solenoid valves to control the emulsion shower and the component cooling.

This hardening unit is used as a part of a training system for determining the energy efficiency of a welding and subsequent hardening process.

First, the workpiece carrier plate is equipped with a compressor wheel and a shaft and retracted into the security cell by pressing a button. From this carrier plate a robot takes the two parts and clamps them in an automated welding system where they are welded. In the following step, the component is extracted by the robot and inserted into the holding fixture of the IHU108. After an optical workpiece recognition, the actual hardening process starts with a setpoint temperature of 1000 °C. Thereafter, the workpiece is quenched by a shower integrated in the inductor.

Through the PLC sequence control, as well as the contactless temperature measurement (pyrometer) multiple heating programs can be defined which allows the training participants to be gradually introduced to the improvement of the energy efficiency. After removing the finished component from the IHU108 it is again deposited on the carrier plate and then discharged out of the safety cell.

This unit is a vertical hardening system for the hardening of small parts and for the annealing of chucks.

This system is equipped with a rotary clamping system with a speed of 100 to 200rpm and a lifting system with 450mm traverse path. With the help of an infrared pyrometer precisely matched to the required hardening temperature, the proper feed rate of the inductor can be calculated. Alternatively it is possible to harden at a constant feed rate. Both options allow the greatest flexibility for different hardening tasks.

The PLC interface allows the creation and saving of up to 100 hardening programs. By connecting the unit to the customer’s corporate network, these hardening programs and hardening data can be exchanged.

This hardening system was developed for the hardening of elevator components (cable guide and securing clamps) and built for a wage labor hardening plant.

The to be hardened components are clamped into a stationary device and heated to approximately 900 °C. Upon reaching the hardening temperature, the entire device is lowered into the corresponding emulsion bath. In addition, workpieces with a length of up to 300mm can be inductively heated in a continuous process and then quenched in the emulsion bath via feed control. This fastest possible cooling of the components ensures a steady and constant hardness. Due to the complete cooling of the hardening component it can be manually removed from the device without risk of burns. Furthermore, due to the use of an emulsion bath, the use of workpiece related cooling showers is no longer necessary.

In order to ensure a 100% constant hardness degree, the emulsion tank is equipped with a temperature sensor and integrated cooling system.

Die ML1000 wurde speziell für das Ein- und Auslöten von Hartmetallschneiden auf einen Sägeblatt-Trägerstahl entwickelt und konstruiert. Das Haupteinsatzgebiet ist dabei der Sägewerksektor.

Die Hartmetallschneide wird hierbei nach dem Einlegen in Position gebracht und sodann mit dem Sägeblatt-Trägerstahl stoffschlüssig verlötet. Das Sägeblatt wird nach jeder Lötung manuell weitergedreht, erneut in Position gebracht und mit einer Hartmetallschneide bestückt. Das dazugehörige Pyrometer in Kombination mit einer SPS-Ablaufsteuerung (Menüführung in deutsch und englisch) ermöglicht eine optimale Temperaturkontrolle und Reproduzierbarkeit.

Die Temperaturregelung kann auch für Folgeprogramme genutzt werden: Beispielsweise wird im ersten Schritt bei ca. 750°C gelötet und bei Erreichen einer vordefinierten Abkühltemperatur von ungefähr 300°C wird automatisch ein zweites Programm für das Anlassen des Lötbereiches auf z.B. 450°C gestartet.

This assembly is a semiautomatic brazing workplace for the inductive brazing of saw teeth onto chain links.

Thereby, a staff member assembles a product carrier with 10 chain links, adds the saw teeth together with the brazing foil and finally fixes them in a retainer jaw. After closing the fixation, the carrier plate is positioned behind a manually lockable safety glass. The following brazing process starts automatically and the 10 brazing joints are clocked one after another, utilitzing a carriage system and an open fork inductor. The completion of the brazing process is followed by an acoustic signal.

The assembly naturally features a PLC as well as a contact-free temperature measuring system (infrared-pyrometer). The carrier plate comes up with an integrated water cooling system to ensure stable brazing conditions.

This assembly is a manual brazing workplace for the soldering of honing tools utilizing a soldering alloy.

The single components of the honing tool are placed within the soldering device with an inductor especially designed for this application. Moreover, this soldering device also consists of a temperature control ensuring an accurate temperature gradiation, ultimately leading to a consistent tool quality. Via the integrated cooling device (air cooling), the liquidus phase of the solder during cooling can be minimized. If needed, this assembly can naturally be equipped with a shielding gas unit.

The utilization of honing tools often describes the last production process of a fine machining treatment and can be applied to nearly every material. It is the goal to positively influence the dimensional accuracy, thus minimizing the frictional resistance.

This workplace has been constructed for the inductive brazing of carbide metals as well as PCD-, PCBN-, and CBN tools.

Thereby, the operator inserts the single components into the brazing device and moves them into a closed, respectively open inductor. The herein described workplace was naturally equipped with a temperature control (infrared-pyrometer) to prevent possible thermal damage (graphitization) of the diamond. Of course, this brazing device can also be equipped with a protection gas unit.

For this special customer order we also integrated a shower to simultaneously harden the workpiece. In combination with the infrared pyrometer, the PLC initializes a hardening shower after the brazing filler metal reaches the solidus temperature. However, this hardening process cannot be compared to regular hardening processes (Hardening normally at approx. 1000 °C / Brazing in this case 700 °C) but nontheless leads to an increased hardness of the workpiece.

The IBU220 was especially designed for brazing and hardening processes in the research and development.

This workplace consists of two 20kW generators and the corresponding heating station with pre-assembled inductors and an electric lifting system with 300mm traverse way. Due to the desired flexibility in the research and development, this assembly has not been outfitted with a set equipment, instead it can be altered depending on the test series. This device has also been equipped with a protection gas unit. Since this device also features a PLC, both induction units can be triggered separately. Additionally, successive heating processes can be realised (Brazing unit 1 done -> Automatic start of brazing unit 2 and vice versa).

This leads to the highest possible flexibility regarding the heat treatment.