A semi-open coil built to the shape of the workpiece generates axial current for uniform case depth, even allowing for deep fillet hardening.
One-Shot Hardening for Reduction of Power Consumption and Warpage
Compared to scan hardening, in which heating and quenching are performed continuously, one-shot hardening has higher thermal efficiency and reduces power consumption per workpiece by approximately 50%. Warpage minimization is achieved through the heating and quenching of the entire workpiece at once.
Hollow Shafts Requiring Shallow Hardening
Shallow hardening of a thin-walled area that leaves the base metal intact requires high frequency, high output, short heating time, and even and rapid quenching.
Fuji Electronics has a proven track record in this area.
High Frequency for Power Consumption Reduction
Power consumption can be reduced by 80% by shifting from carburization to IH hardening.
Only necessary areas are hardened, minimizing post-hardening warpage.
One-Shot Hardening for Continuous Casing
One-shot hardening ensures a continuous casing, even in areas that are difficult with scan hardening, such as steps and grooves. Scan hardening can also cause overheating in large steps, which is not an issue with one-shot hardening.
Constant Velocity Joints (CVJ)
One Converter for Multiple Hardening Locations
By switching between three frequencies, one multi-frequency converter can harden ball grooves, roller grooves, spline grooves, and shafts.
Long-Lasting Multi-Turn Coils
Using a spiral multi-turn coil with four or more turns for the hardening of groove sections provides an ideal casing and a long coil life of more than 200,000 shots.
Cooling Technology to Prevent Soft Spots
In cooling groove sections, internal air is strictly suppressed to prevent the formation of soft spots.
Concentrators to Prevent Cracking of Groove End Face
Concentrators are used to dissipate excess heat for the groove end face casing, and the optimal shape and material are used to prevent cracking and melting.
Precision Gears and Contours
Preheating at a low frequency to the target depth, ultra-short main heating at a high frequency and high power, and precisely controlled immersion cooling makes contour hardening ideal for small-module gears.
Low-Warpage Hardening (Flat Hardening, Fillet Hardening Supported)
The semi-open coil hardens while tracking the rotating workpiece to minimize warpage.
Power Reduction System
The case depth is adjusted while the power is adjusted according to the rotational angle of the workpiece, so there is no difference in the hardened range of the pin top side and the balance weight side. The post-polishing core is precisely rounded.
We supply coils and thin disk transformers that achieve a 10.5mm hardening width.
Trend and Power Monitoring Systems
The positional relationship between the workpiece and coil significantly affects quality. Fuji Electronics simultaneously monitors physical movement and hardening conditions through the combination of our Trend Monitoring System, which monitors the positional relationship with power, and our Power Monitoring System, which monitors the total power input to the workpiece.
In order to meet equipment height restrictions for gantry use and size limitations for shipping containers, we have achieved a significant downsizing of our equipment (volume ratio: about 1/3, height: 2000mm).
The coil moves eccentrically, tracking the rotating cam, to ensure the top and bottom gaps are kept constant, in order to form an even casing across the entire body. This method prevents cracking on the cam top due to overheating and post-process grinding.
A proprietary concentrator ring prevents unnecessary heating of journals to reduce warpage.
Coil Position Auto-Adjustment (Optional)
Cam conditions and coil/transformer positions can be automatically adjusted to accommodate various cam models.