Innovative heating Induction heating solutions
www.ghinduction.com info@ghinduction.com
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Innovative heating
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About GH Induction Since 1961 we are a specialized group of companies in induction heating solutions for the industry which is part of Park Ohio Holdings Corp. More than 4.000 systems make GH a strong supplier that reinforces its experience and know-how thanks to the synergies working in different sectors.
Our main induction solutions are developed for: Heat treatment
Joining processes
Heating in general
Hardening
Brazing
Curing
Tempering
Soldering
Straightening
Annealing
Welding
Preheating
Normalizing
Bonding
Forging
Stress Relief
Shrink fitting
Many others
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Innovative heating
What is innovative heating? Innovative Heating is how we apply our induction technology, services, innovation and know-how to meet your objectives in the most optimal way: · Increasing quality products. · Improving final customer satisfaction. · Maximising production rates. · Optimizing capital expenditure. · Reducing Total Cost of Ownership. · Increasing asset life-span.
Why is this necessary? Because every business is unique and every industry is different. We take your unique situation as the starting point. That’s why GH adopts a unique approach to every client challenge.
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Some of our customers: AMERICAN AXLE
BLACK & DECKER
FAW TOKICO
INGETEAM
ROBERT BOSCH
ABB
BWI
FEDERAL MOGUL
JOHN DEERE
SAFRAN
ALSTOM
CASCADE
FIAT
JTEKT
SCANIA
AMETEK
CIE AUTOMOTIVE
FORD
KYB
SIEMENS
ARCELOR
DAEWOO
FREZITE
LAND ROVER
SKF
AUDI
DAIMLER
FUJIKURA CABLE
MAHLE
SKODA
AUTOVAZ
DANA
GAMESA
MERCEDES BENZ
TENARIS
BAHRA CABLE
DEFONTAINE
GENERAL ELECTRIC
NEAPCO
THYSSENKRUPP
BENTELER
DENSO
GESTAMP
NESTLE
TROESTER
BHARAT FORGE
DEUTZ DITER
GKN
NEXTEER LINGYUN
VALEO
BILL FORGE
EATON
GENERAL MOTORS
NKT
VALLOUREC
BMW
EDAG
HERO HONDA
NTN
VICINAY
BODYCOTE
EMBRAER
HILTI
OPEL
VOLVO
BONFIGLIOLI
EPC
HYUNDAI-WIA
PSA
VOLKSWAGEN
BORG WARNER
ESSER
ILJIN
RENAULT
ZF
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Innovative heating
The key factor: how to apply induction heating efficiently Ensuring the technical viability of applying induction heating to your processes is crucial to the success of the investment in induction. GH makes this a priority by: · A dedicated team of delivery experts. · Simulation and full laboratory testing. · Experience and ability to innovate. Then we can take care of your induction project until your production is running and beyond. We are specialized in turn-key solutions.
3D heating simulation.
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How we work in your induction project: Turn-key project Understanding your requirements Induction heat application (Temperature) Part dimensions and material Production (cycle time) Level of automation Integration in the production
Solution proposal Power supply, oscillator and inductor Cooling systems Handling machine or system Control system
Process Viability Deep understanding of your objectives Simulation, Laboratory and Metallurgy tests Process development and/or improvement
Turnkey project
After-care Service On-site support Maintenance Training Refurbishment
GH CAPABILITIES
Technical expertise - Experience knowledge Innovative ideas and resources
Project management Manufacturing and quality tests Delivery, starting up and commissioning
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Innovative heating
Your objective Our solution Systems and technologies are combined to meet your objective which is the main driver to design our solution.
Strengths · 100% GH technology · Energy efficiency · Turnkey projects · Customer services · Full process control Application · Hardening · Tempering · Annealing · Stress Relieving · Brazing · Soldering · Welding · Shrink fitting · Straightening · Heating Production · Production rate · Cycle time · Automation · Integration
Inductor Process Development Inductor Manufacturing - 3D printed shower - 3D printed coil (PATENT) - Rotating inductor (PATENT) - Split inductor (PATENT)
Cooling Systems For power supply elements For hardening process
Power Supplies IGBT, MOSFET, SiC - Transithermic, MSG - inKompac, inCube, Aghile - Oscillator supply
le
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Handling Machine (if apply)
Part tracking
Continuous Quenching System (CQS)
Marking systems Reading and weighting systems OPC Interface
Machine Control PLC, CNC based Machine monitoring Smart operation
Quality production Real-time Process Monitoring System (IPM)
Final verification Eddy current system integration
Load/Unload systems
Other processes Tempering tunnel Washing machine
Innovative heating
Power supplies The heart of induction for any application Solid state families Transithermic
For the most demanding industries
inKompac
Compact and integrable. Series
inCube
Compact and integrable. Parallel
Aghile
Mobile and everything included
MSG
Compact for multi-output (up to 8)
GH offers all necessary components to achieve the required power frequency and cooling for the system. Power
10 kW to 2000 kW
Frequency
0.5 kHz to 400 kHz
Power (kW) 10
25
50
75
100
0,5
3 10 20 50 100
200
250
MELTING
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Frequency (kHz)
10
TEMPERING SHRINK-FITTING BONDING CABLE PREHEATING HARDENING BRAZING SOLDERING SEALING
150
TUBE WELDING 400
Oscillator: flexibility and efficiency · Series or parallel (LLC) resonant circuit configurations · Conventional transformer. For flexibility. Extensive transformation ratio of turns. · Toroidal output transformer. To maximize the efficiency.
600
700
FORGING
2000
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Transithermic
inKompac
IGBT, MOSWELD SIC [25, 2000] kW, [0.5, 400] kHz Tailored configurations Single, multioutput (up to 8) and dual frequency
Operation · AutoScan: finding the optimum frequency · Power regulation from 0-100% · Heating programs (up to 15) · Low impact in AC main
MSG
[10, 30] kW, [4, 300] kHz Compact size Easy integration
Monitoring · High accuracy Energy Monitoring · Measurement of I, V, P & E · Events log · Dew point control system
Communication · Wiring signals · Field bus: Profinet, DeviceNet, Ethernet/IP and others
Transithermic family
Multioutput inCube
inKompac
inRobot system
Aghile
The most advanced technology: SiC transistor. · Extreme power density – Reduced layout. · Robustness.
· Wide range of frequencies – Combination of hardening and tempering with one inductor. · Reduced operating expenses.
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Innovative heating
Inductors
Magnetic field concentrators
Quenching inlet
Make the difference Inductor is one of the most important components of the overall induction heating system. Quenching showers
A well-designed inductor provides: · Proper heating profile for the part · Temperature uniformity · Maximizing efficiency · Easy positioning of the part
Inductor connection to output plates
Output plates for power supply connection
Example: Main manufacturing steps
3D heating simulation OPTIMA service
Design of the coil
Coil manufacturing by: brazing, machining, 3D printing
Assembled coil in inductor installed in machine
Internal coil design. In case of 3DPCoil
Hardening profile
Part to be treated
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3D Inductors Patented technology 3D printed coils based on Electron Beam Melting technology for additive manufacturing.
Benefit
Key features
OPEX reduction Extreme inductor lifespan
No brazed joints, no weak points Improved cooling, interior section design
Changeover time reduction
Dimensional accuracy and repeatability in inductor duplication
Adaptation of the inductor
Direct printing simplifies complex geometries
More info: www.3dinductors.com
Rotating inductor For cases where turning the workpiece becomes complex or impossible. · Heat treatment improvement. · Mechanical simplification. · Maintenance reduction.
99,9% purity 100% density
Measured copper purity by CERN: RRR>250 Superconductor
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Innovative heating
Application examples Make the difference GH has developed hundreds of applications, ask our team if you are interested in a specific case. The following are examples of our applications:
Heat treatment
Joining processes
Heating in general
Hardening
Brazing & soldering
Shrink fitting
Tempering
Bonding
Preheating
Normalizing
Super alloy preheating
Straightening
Stress relief
Welding
Forging
Hardening of truck drive axle
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Heat treatment In automotive driveline and transmission Plunging joints Hardening of tracks and female stems.
Ball Outer race Hardening and tempering stations in machine of bell and stem.
3DP coil for bell
Inner race Very high-production hardening of inner race. Built-in Continuous Quenching System.
6” cycle time
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Innovative heating
Shafts Hardening by vertical scanning. The inductor and shower move. vertically. Shaft distortion minimized.
Hub – Outer Race The fastest production. 4” heating time. Split inductor (patent). Superior heat treat pattern through the control of the air gap along the inner diameter.
Spindle - Inner Race High production hardening machine with CQS system and 3D printed showers and tempering tunnel.
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In automotive suspension Shock absorber rod Hardening and tempering by scanning. Centerless based machine.
Camshaft slot Hardening of the slot at the end of the camshaft. A 3D inductor was used.
Sintered parts Sintered sprockets Single shot hardening Uniform heating with rotating inductor systems.
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Innovative heating
Heat treatment General industry Different parts
Customized hardening and tempering machines or standard TVK family models.
TVK family. Family of compact vertical machines with easy operation and maintenance. Different models depending on the part dimension and weight. Maximum part length: 1000 mm.
TVK Single or Double
D model – two different treatments in the same TVK machine
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TVK for multiple operations Compact machines for several simultaneous operations on a part. Ideal for medium production volumes.
Large size parts
Hardening of big shafts with different diameters. The inductor follows the shape of the parts.
Heavy duty
Several CNC-controlled axes. Vertical & horizontal scanning.
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Innovative heating
Tools and fasteners Automotive and trilobular Automotive and trilobular screws, concrete and screws,fasteners, concrete and railway pliers, railway fasteners, pliers, screwdrivers, wrenches screwdrivers, and more can wrenches be treated. and more can be treated.
Tool holders Tool holders heat treatment. Automated change of inductors reduces dramatically stopagges in production.
Automated inductor change systems (AIC)
Part reference 1 Pa rt re fe re n c e 1
Automated interconnections change of: cooling, quenching, electrical, air Ideal for a reference with many treatments. Ideal for different references without manual changes.
… ... Pa rt re fe re n c e n
Part reference n
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Large Slewing Bearings Horizontal hardening of teeth and tracks
3DP coil for teeth OCTG pipe Stress Relieving For elimination of stress in pipe ends. Between 450ºC and 650ºC with high temperature uniformity.
Railway Hardening and normalizing High-speed switch blade head hardening and normalizing.
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Innovative heating
Joining processes There are hundreds of applications where induction heating can be applied. Joining both parts with a filler metal is a widely utilised solution in the industry.
Brazing and soldering
Short-circuit ring brazing in an industrial rotor. Heat exchanger and copper tube brazing.
Welding
Metal tube and profile. The base material is raised to a high temperature to exceed its melting point.
Bonding and curing
Bonding for car doors. It is an adhesive curing process.
Super alloy heating for welding
Pre- heating of super alloy aerospace blade for weld repairing in argon atmosphere.
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Heating in general The production efficiency of traditional heating sources can be drastically improved by replacing them with induction. Introducing induction to pre or post heating also helps to improve production significantly.
Shrink fitting
Hydro generator shaft and heavy plate. Union by mechanical interference of two pieces.
Straightening
Heating for deck and bulkhead straightening to eliminate distortion. It replaces flame torches.
Preheating
In-line cable pre-heating before extrusion. For copper and aluminium conductors. Automated inductor change.
Forging
Bar heating for forging in the manufacturing of off-shore chains.
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Innovative heating
Mobile stand-alone heating system Aghile family · Versatile and mobile heating system. · All in one box (oscillator and cooling included). · Just plug the inductor and play.
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Aghile is a multipurpose induction heater for noncontinuous heating applications such as brazing, hardening, straightening, drying, shrink-fitting, preheating, post-heating, die hardening, etc.
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6 7 8
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1 2 3 4 5 6 7 8 9 10 11
360º articulated boom Jig boom Hand grip Flexible MF cable Foot switch Power supply Oscillator Chiller Siemens PLC Permanent mode Up to 16 recipes
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Multioutput power supply to be integrated MSG family for low power applications Ideal for integration in automated production lines with several low power induction heating such as shrink fitting, curing, coating, etc. · Power output: 5kW, 10kW, 15kW · Frequency [10, 300] kHz · Up to independent 8 outputs
p1,f1 p2,f2 ... p8,f8
Power supply cabinet with cooling on the bottom. Application examples:
Adhesive bonding of car doors, hoods, etc
For EV motor heating processes: stator trickling and powdering, rotor shrink fitting, etc.
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Innovative heating
Final step, production control and monitoring Real-Time Induction Process Monitoring (IPM)
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1 Actual value. 2 Min. Value.
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4 Monitored parameter. 3 Max. Value
Power supply parameters in real-time during a heating process.
IPM system monitors the parameters involved in the processes (up to 64) in order to identify NOK parts. NDT system based on Eddy Current (ultrasonic) complements the supervision.
BENEFITS · Reliable production. · Continuous improvement. · Destructive testing reduction.
Quenching medium control, critical in hardening.
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Tracking Production
Remote monitoring
Induction, one step in the manufacturing path
Always close to you
Data on parts a is collected and transferred to corporate systems through communication interfaces for analysis.
All machines are connected to GH via a secure connection.
OPC interface for data monitoring
PLC
OPC Server
Induction Machine Part Tracking
Data Collection Communication interface for remote monitoring
OPC Interface
OPC Client Software
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Innovative heating
Induction 4.0 Enabling the advanced manufacturing
GH solutions include digital enabler technologies within the industry 4.0 framework. The aim is to equip all our customers to efficently meet the changing requirements of their end consumers.
Robotization
ConnectAR service
OPTIMA Service: 3D heating simulation and 3D Inductors
Automated inductor change
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Innovative heating
Beyond customer services Installation, onsite support and system maintenance throughout the entire production lifecycle are all included in our services.
Maintenance and technical assistance GH Technical engineers support customer in their daily operations and in their preventative planning. This service is made possible by our global service network. ConnectAR Service Collaborative remote assistance service based on Augmented Reality improving productivity and reducing downtime for our customers. OPTIMA Service It combines two digital technologies (3D simulations with 3D Inductors) and the knowledge and experience of the GH technical team to find the most optimal inductor design. Inductor training A set of training programs to understand GH induction solutions and the induction heating technology is available. Repair & Spare inductors A repair service and spares are offered for GH inductors. For advanced manufacturing inductors, the industrialized process allows high dimensional accuracy in the copies and shorter delivery times for 3D Printed Coils.
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With you wherever you are The customers are worldwide spread so GH Induction counts with a global service network. This network is composed of their own companies in different countries and with the support of the rest of the group that belong to.
Other induction PKOH companies GH Induction companies
GHCOM017004EN.5
www.ghinduction.com info@ghinduction.com
Company of Park Ohio