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

 

1. Heating Gears:

 

l        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℃

l        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℃

1. Heating Gear ring

 

l        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℃

 

 

 

l        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℃