0102030405
China Suppliers Industrial Induction Heating Machine for Gear and Chainwheel Forging – 15-60KW Power Output
Product Description
Industrial-Grade Durability – Heavy-duty cooling system (water/forced air) for 24/7 operation in demanding workshop environments.
Automation-Ready – CNC-compatible control interface for programmable heating cycles, ensuring repeatable forging quality.
Ideal for:
Gear & Sprocket Manufacturing – Precinduction heating for distortion-free hardening.
Chainwheel Forging – High-efficiency heating for industrial conveyor systems and heavy machinery.
Custom Industrial Diathermy – Adaptable for large-scale metalworking with modular coil designs.
Application Scope
1. Industrial Gear Manufacturing
Precision Forging: High-frequency induction heating for spur gears, helical gears, and bevel gears (up to 1200°C) with uniform heat penetration.
Hardening & Tempering: Optimized for carbon steel, alloy steel, and hardened gear materials to enhance wear resistance and durability.
2. Chainwheel & Sprocket Production
Heavy-Duty Forging: Efficient heating for industrial conveyor chainwheels, motorcycle sprockets, and agricultural drive components.
Custom Coil Compatibility: Adjustable induction coils for large-diameter sprockets (up to 500mm) and high-volume production.
3. Automotive & Machinery Components
Transmission Parts: Induction heating for gear shafts, synchronizer rings, and differential components in automotive manufacturing.
Heavy Machinery: Supports mining, construction, and marine gear forging with high-power (15-60kW) diathermic processing.
4. Custom Metalworking & Repair
Tool & Die Maintenance: Precision heating for mold repair, press forging dies, and industrial tool reshaping.
Flexible Applications: Compatible with batch forging, automated CNC lines, and manual workshop operations.
Ideal for industries: Automotive, aerospace, heavy machinery, and metal fabrication.
Configuration and Performance
Industrial Induction Diathermic Heating Machine for Chainwheel & Gear Forging
1. Core System Configuration
| Power Unit |
Output Power: 15-100 kW (adjustable) Frequency Range: 1-150 kHz Input Voltage: 3-phase 380V, 50/60Hz (industrial-grade power supply) |
| Heating Station |
Induction Coils: Customizable copper coils (ID 50-500 mm) for gears/sprockets of varying sizes Cooling System: Closed-loop water cooling (flow rate ≥20 L/min) with overheat protection |
2. Performance Parameters
| Heating Capacity |
Max Temperature: 1,250°C (±10°C control accuracy via PID) Heating Speed: 5-30 sec for 20-50 mm thick steel (energy efficiency ≥92%) Uniformity: ≤±15°C temperature gradient across workpiece |
| Material Compatibility |
Metals: Carbon steel (AISI 1045/1060), alloy steel (4140/4340), stainless steel (304/316) Applications: Gear blank heating, sprocket hardening, chainwheel tempering |
3. Control & Automation
Operation Interface:
Touchscreen with preset programs for common forging profiles. PLC integration for automated production lines (RS-485/Modbus support).
Safety Features:Overcurrent/overvoltage protection, emergency stop button, IP54-rated enclosure.
Typical Applications:
- Automotive gear forging
- Mining conveyor sprockets forging
- Heavy machinery components
- Custom metalworking repairs
Technical Specifications
1. Power System
| Input Power | 380V/415V ±10%, 3-phase, 50/60Hz |
| Rated Power | 60-100kW |
| Frequency Range | 30-150kHz (auto-tuning for optimal heating depth) |
| Duty Cycle | 100% continuous operation |
2. Heating Performance
| Temperature Range | 200-1250°C (PID controlled ±5°C) |
| Heating Speed |
5-15 sec for small gears (ø50-100mm) 20-40 sec for large chainwheels (ø300-500mm) |
| Efficiency | ≥90% energy conversion rate |
3. Mechanical Configuration
| Dimensions | 1000×800×1200mm (L×W×H) |
| Induction Coils | Multi-turn copper coils (ID 30-600mm) with quick-change design and water cooling channels |
| Cooling System | Water flow: ≥40L/min @ 0.2MPa; Temperature alarm at >45°C |
4. Control System
| Operation Interface | 10" touchscreen with 8 preset programs |
| Monitoring | Real-time temperature/power monitoring |
Main components:
Frequently Asked Questions
What is the maximum heating temperature of this induction heating machine?
The machine can reach a maximum temperature of 1,250°C, with a PID-controlled temperature range of 200°C to 1250°C and a control accuracy of ±5°C to ±10°C.
Which metal materials are compatible with this heating system?
It supports a wide range of metals including Carbon Steel (AISI 1045/1060), Alloy Steel (4140/4340), and Stainless Steel (304/316) for various gear blanks and sprocket hardening applications.
What are the cooling system requirements for continuous operation?
The system utilizes closed-loop water cooling requiring a flow rate of ≥20 L/min to ≥40 L/min at 0.2MPa. It features built-in overheat protection and a temperature alarm that triggers if the water temperature exceeds 45°C.
How fast can this machine heat gears and chainwheels?
Heating speed varies by size: it takes 5-15 seconds for small gears (ø50-100mm) and 20-40 seconds for larger chainwheels (ø300-500mm), ensuring high energy efficiency (≥90%-92%).
Is the equipment compatible with automated CNC production lines?
Yes, the machine is automation-ready. It features a CNC-compatible control interface, PLC integration with RS-485/Modbus support, and a 10" touchscreen interface with preset programs for automated operations.