2003 ENGINEERING DESIGN AND MANUFACTURING SERVICES, INC. INDUCTION HEAT TREAT COMPLETE SYSTEM

MACHINE SPECIFICATIONS:
Machine for hardening and fixture for quenching spiral bevel ring gears in the size range between 220 mm and 450 mm on the outside diameter up to 100 mm wide.  The general configuration of the machine includes Lift Rotate Induction Heating in the one station and automatic part transfer from the heat station into a single head Press Quench.  All machine components, controls, and power supply are constructed on a common machine base. An infrared temperature sensor will be used for closed loop temperature control.  Machine functions are controlled by an Allen Bradley family PLC and IDT operator interface touch panel.  Machine diagnostics, part recipes, and data archival is performed by the EPIC Diagnostic system.  The production rate of the machine will be controlled by the quench rate of the press.  

HARDENING SYSTEM CONFIGURATION:
*EFD 400 kW, 4/6 kHz Power Supply with Output Matching Station
*Power Supply buss and Coil Receptacle
*Distilled Water System.  All stainless steel construction with all inter-connect piping of non-ferrous metals. System heat exchanger is to be sized for operation with plant supplied cool water loop (90 degree F maximum).
*Heating Station.  The heating station is equipped with a rotating spindle.  The lift rotate has two positions: load/unload position and heat position.  The heat positions are programmable through a servo control to accommodate the different part lengths. Total lift travel is ten (10) inches.  The work piece is supported with dedicated top jaw tooling appropriate for each of the different work pieces.  Heating is accomplished within an atmosphere chamber with nitrogen cover gas.  Part loading/unloading is to be automatically done.

QUENCH PRESS:
The Press frame is a two post frame design to support an electrically powered servo controlled ball screw.  The quench press is automatically loaded and unloaded.  The press location and pressures are controlled by the PLC with feedback from linear transducer and a pressure transducer integral to the press.  All operating parameters for the press are recipe driven from the control system.  

QUENCH SYSTEM:
A quench re-circulating system is provided for the hardening system.  All critical process parameters relative to the quench system; pressures, temperature and levels are monitored by the diagnostic and control system.  The quench system heater is sized so that maximum startup from room temperature can be accomplished in one-half hour or less.  Filtration is accomplished with a strainer at the pump and bag filtration to ensure minimum maintenance and maximum quench-ant life.  

MACHINE CONTROL:
An Allen Bradley RS Logix 5000 family PLC is used to control all system operations through discrete I/O.  The PLC will interface with the system process sensors and with the diagnostic computer.  The operator interface is an IDT PanelMate touch screen panel.  The machine control will be located on the machine base.  The control system is housed in a NEMA 12 rated enclosure.  

PROCESS MONITOR/DIAGNOSTIC/RECIPE MANAGEMENT SYSTEM:
A personal computer is utilized as the hardware platform for a data archival process monitor.  The software platform is Windows based with Wonderware software.  All process variables are monitored in real time and archived for full diagnostic process control and trend analysis.  Statistical process control tools are available for further diagnostic review.  Fault monitoring is displayed in real time with interactive screens within every module of the system.  

The receipt management function is performed in an additional module of the same control system. Downloading of production recipes are supervised by the system, prompting the operator through the part changeover module. Operator acknowledgement is required at each step of the changeover before the new recipe will download. Creation of new part recipes or editing of existing recipes are password protected.  An online print viewer provides access to part drawings at any time during the changeover or run sequence ad machine drawings during maintenance or troubleshooting activities. Preventative maintenance routines are run in an additional module that requires operator acknowledgement.