FOCO’s advanced dual-station induction hardening system revolutionizes high-volume production for automotive and heavy machinery manufacturers. Designed specifically for shafts and pins (16–120 mm diameter), this 300 KW powerhouse processes two workpieces simultaneously, slashing cycle times while delivering uniform surface hardening at depths of 2–10 mm.
Industry Challenge
Mass-producing hardened shafts for engines, transmissions, and hydraulic systems demands extreme consistency. Traditional single-stage quenching creates bottlenecks, while uneven heating leads to premature part failure. Manufacturers need:
- ≥50 HRC surface hardness for wear resistance
- Minimal distortion (<0.1mm) to avoid post-machining
- Throughput exceeding 100 parts/hour
FOCO’s Turnkey Solution
Our integrated system combines brute power with surgical precision:
- Simultaneous Dual Processing: Two independent workstations handle shafts/pins concurrently. Operators load one station while the other runs—zero idle time.
- Smart Frequency Control: 5–45 KHz auto-adjusting frequency ensures optimal heating for diverse diameters (from 16 mm pins to 120 mm drivetrains).
- Multi-Segment Scanning: Program heating patterns for tapered shafts or flanged pins via PLC. Three-stage scanning prevents edge overheating.
- Industrial-Grade Cooling: Dual-circuit chilling—dedicated chiller for rapid workpiece quenching (≤3 sec), open cooling tower for continuous machine protection.
Technical Superiority
- Power Core: 300 kW IGBT power supply with 95% energy efficiency
- Precision: Laser-aligned coils maintain ±0.5 mm gap tolerance
- Automation: Siemens PLC with touchscreen HMI stores 50+ recipes (e.g., “SUV drive shaft,” “excavator pin”)
- Adaptability: Quick-change coil kits for sudden product switches
Proven Results in Automotive Production
A Tier-1 drivetrain supplier achieved:
- 120 parts/hour sustained output (vs. 65/hr on single stations)
- 15% energy savings vs. conventional furnaces
- Zero scrap from distortion (all parts within 0.08mm tolerance)
- HRC 52–55 hardness across 10,000+ shaft batch
The system’s “parameter download” feature lets engineers push new settings from CAD files—ideal for just-in-time manufacturing. FOCO also provides lifetime coil redesigns for evolving part geometries.
Gallery of Dual-Station Shaft & Pin Hardening
