Abstract:
An arrangement for induction hardening a part including a pair of separate inductors electrically isolated from each other and configured to substantially surround a part when brought into close juxtaposition with each other. The inductor sections are powered by respective secondary inductor loops brought into close juxtaposition with a primary inductor loop connected to an ac power source which induces an ac current in each inductor section.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. provisional application No. 61/278,043 filed on Oct. 2, 2009, incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    This invention concerns induction hardening which is widely used in industry to harden such parts as cam shafts, crank shafts, etc. In this process an inductor surrounds a section of the part, and a high frequency voltage is applied to the inductor. This induces a current in the surface of the part (to a variable depth set by design), rapidly heating the same to a desired temperature. A flow of quenching coolant is then directed at the part, thereby hardening the surface of the part to the hardness and depth desired. 
         [0003]    In the conventional arrangement, the inductor (typically a single turn coil) is constructed in two halves in order to allow positioning of the part within the coil by a clam shell opening of the inductor closed around the part when the ends of each half are pivoted together. The coil halves can also be separated by linear motion and then brought together to surround the part. In this arrangement it is necessary to make an electrical connection between the inductor half coil ends in order to complete the circuit and cause current to flow through both coil halves. 
         [0004]    Power from a high frequency power source is applied to the inductor to cause a high frequency current to flow through the connected inductor coil halves. 
         [0005]    Such electrical connections must be made with care to insure a proper flow of power through the complete inductor coil, slowing the process of loading the part. Such connections are subject to wear and present a maintenance burden in this application. This requirement makes automation of part loading somewhat impractical. 
         [0006]    Another problem often encountered is the formation of gaps in the electric field induced around the inductor which would create unevenness in the hardening obtained in the part, necessitating rotation of the part in the inductor coil in order to prevent this, complicating the equipment needed and slowing the completion of the hardening part heating cycle. 
         [0007]    It is an object of the present invention to provide an arrangement and method of powering an inductor formed of two half coils which does not require the making and breaking of an electrical connection between the two inductor half coils. 
         [0008]    It is a further object of the invention to provide such arrangement and method which does not create gaps in the electrical field created by the inductor coil to and thereby not require any rotation of the part during the induction hardening process. 
       SUMMARY OF THE INVENTION 
       [0009]    The above recited objects and other objects which will be understood upon a reading of the following specification and claims are achieved by an inductive coupling in common simultaneously to both inductor coil half sections of a two part inductor coil allowing separation to position a part therein, inducing a high frequency voltage in each inductor coil half section, while not requiring a direct electrical connection between the inductor coil half sections. This is accomplished by applying the power to primary conductor loop which is positioned between respective secondary conductor loops connected to the respective inductor coil half sections below these half coil sections. 
         [0010]    Thus, the necessity for an electrical connection between the inductor coil half sections is eliminated and the sections can be quickly moved apart and back again together for loading and unloading of the part or for shifting the part to bring another area of the part into the inductor coil. This feature facilitates automation of the process and allows simultaneous treatment of many or all of the areas of work pieces such as cam shafts and crank shafts by a plurality of inductor coils to greatly speed the cycle times. 
         [0011]    In addition, it has been found that no gaps in the induced electrical currents result such that the part need not be rotated, further simplifying the equipment necessary. 
     
    
     
       DESCRIPTION OF THE DRAWING FIGURES 
         [0012]      FIG. 1  is a partially exploded end view of an induction hardening arrangement with a diagrammatic depiction of a primary power source. 
           [0013]      FIG. 2  is a side view of the arrangement shown in  FIG. 1  in the operative position of the main components. 
           [0014]      FIG. 2A  is a pictorial end view of the components shown in  FIG. 2 . 
           [0015]      FIG. 3A  is a separated view of the inductor coils and primary loop components included in the arrangement shown in  FIG. 1 . 
           [0016]      FIG. 3B  is a pictorial view of the components shown in  FIG. 3 . 
           [0017]      FIG. 4  is an enlarged pictorial view of the primary loop component shown in  FIGS. 3 and 3A . 
           [0018]      FIG. 5  is a side view of the components of  FIGS. 3 and 3A  in the position assumed during induction heating of a part. 
           [0019]      FIG. 6  is an end view of the components shown in  FIG. 5 . 
       
    
    
     DETAILED DESCRIPTION 
       [0020]    In the following detailed description, certain specific terminology will be employed for the sake of clarity and a particular embodiment described in accordance with the requirements of 35 USC 112, but it is to be understood that the same is not intended to be limiting and should not be so construed inasmuch as the invention is capable of taking many forms and variations within the scope of the appended claims. 
         [0021]    Referring to the drawings and in particular  FIG. 1 , an arrangement  10  according to the invention includes a pair of inductor half coils  12 A,  12 B, each held in recesses in a respective cooling block  14 A,  14 B in the manner well known in the art. 
         [0022]    During use, coolant is directed under pressure into inlets  16 A,  16 B which passes into an array of radial internal passages  18 A,  18 B which open into the semicircular recesses  20 A,  20 B adjacent spaced apart partially circular segments  22 A,  22 B to quench the part  24  after induction heating to create a case in the well known manner. The inner coil sections  22 A,  22 B are spaced apart to allow the entrance of quenching coolant via passages  18 A,  18 B. 
         [0023]    The inductor coil half sections  12 A,  12 B also include outer partially circular segments  24 A,  24 B more widely spaced apart to accommodate the passages  18 A,  18 B respectively. 
         [0024]    The segments  22 A,  22 B are formed of copper and partially circularly shaped to encircle the part  25  when brought into a position next to each other as seen in  FIG. 2A and 6 . The configuration will vary to match any particular shape and area size of the part  25  as known in the art. 
         [0025]    The lower ends of each of the segments  22 A are integral with a conductive connector leg  26 A,  26 B descending to a connection with one side of a pair of generally square secondary inductor loops  28 A,  28 B which are split at  30 A,  30 B with insulator strips  31 A,  31 B inserted therein to preclude any electrical contact or arcing between the two ends thereof. An insulator strip  32  is also adhered to one leg  26 A to insulate the two legs  26 A,  26 B when brought together during induction heating of a part  25 . 
         [0026]    The outer return segments  24 A,  24 B are connected at their lower ends to conductor legs  34 A,  34 B joined to the inductor loops  28 A,  28 B at the other side of splits  30 A,  30 B from the side connected to legs  26 A,  26 B. 
         [0027]    The upper ends of segments  22 A,  22 B,  24 A,  24 B are connected together by joining pieces  36 A,  36 B, with in insulator strip  38  adhered to upper straight ends of the inner coil segments  22 A to prevent any contact or arcing. Insulator strips  40 A,  40 B are interposed between legs  26 A,  34 A and  26 B,  34 B for the same purpose. 
         [0028]    Each side of each inductor loop  28 A,  28 B has secured thereto a flux concentrator lamination  42 A,  42 B using a thin iron or FLUXTROL™ laminations of a thickness (such as 0.003 inches) suited to the particular part hardening application in the manner well known in the art. 
         [0029]    Each secondary inductor loop  28 A,  28 B has coolant inlets and outlets  44 A,  44 B to allow circulation of coolant in hollows therein (not shown). 
         [0030]    Both of the secondary inductor loops  28 A,  28 B are aligned with a single primary inductor loop  46  split at  48  with in interposed insulator strip  50 . The primary loop  46  has an insulator coating (typically 0.015 to 0.020 inches thick) as of nylon applied in a dip process which is durable to withstand wear. Each side is integral with a connector leg  52 A,  52 B joined to a respective terminal bar  54 A,  54 B in turn connected to a primary AC power source  60  such as to apply 30 Khz thereto as shown diagrammatically. 
         [0031]    The terminal bars  54 A,  54 B have coolant entry/exit ports  56 A,  56 B allowing circulation of coolant through passages in the terminal blocks  54 A,  54 B and loop  46 . An insulator strip  58  interposed between the terminal blocks  54 A,  54 B to prevent contact or arcing. 
         [0032]    Accordingly, a single primary loop inductively powers two electrically isolated coils without any electrical connection between the two coils. All that is required is that they be moved in to be immediately adjacent a respective side of the primary loop  46 . 
         [0033]    Additional turns could be provided of the primary loop  46 , as necessary to achieve a desired power level but a one-to-one equal area of the primary loop  46  and secondary loops  28 A,  28 B has successfully been operated as described. 
         [0034]    The two assemblies  12 A,  12 B can be mounted for linear in and out movement to capture a part section which allows axial movement of the part to locate a different area for hardening between the coil sections or pivoted to allow a clam shell opening motion. Multiple coil section units can be used to simultaneously harden multiple sections of a part simultaneously. Turn table arrangements can also be used to bring variously configured inductor section pairs together for different sections of the part. 
         [0035]    It has been found that by inductively powering two electrically isolated coil halves y the arrangement shown, dead spots are avoided so that rotation of the part is not necessary.