Are you still troubled by the low efficiency, high energy consumption and unstable quality of your old induction heating equipment? The XK100 Induction Heating Machine for Wire Cutters provides you with a one-stop solution:
- 40% Energy Saving: Compared with traditional equipment, it consumes power only during the heating phase, cutting annual electricity costs by over 100,000 yuan.
- Precision Quality Control: Equipped with Siemens PLC and touch screen, the heating parameter accuracy reaches ±0.5%, and the consistency of quenching layer depth hits 99%.
- Multiple Safety Protections: 7-fold safeguards including over-temperature, water shortage and over-voltage protection, ensuring zero risk of safety accidents.
- Flexible Customization: Compatible with more than 10 types of tools such as wire cutters, diagonal cutters and long-nose pliers, with fixture replacement completed in only 15 minutes.
- High-Efficiency Cooling: Combined with water chiller and plate heat exchanger, the equipment volume is reduced by 30% and cooling efficiency is improved by 25%.
Workpiece literacy
Core Value of Head Quenching for Wire Cutters
The head of wire cutters and diagonal cutters is a key stress-bearing part. It requires induction heating quenching to enhance hardness (HRC 58-62) and wear resistance, extending the tool service life by more than 3 times. Common processing materials include high-carbon steel (e.g., 45# steel) and alloy steel (e.g., Cr12MoV). However, traditional processes are prone to issues such as uneven heating deformation, oxide layer residue, and quenching layer depth fluctuation, which directly result in a rejection rate as high as 5%-8%.
Process Flow Overview
The XK100 enables efficient operation throughout the entire process of loading → parameter setting → induction heating → quenching & cooling → inline inspection → unloading, with core processes precisely controlled by a digital system to eliminate human errors.
Key points of each link
- Loading & Fixture Adaptation
- Customized Quick-Change Fixtures: For different types of pliers (e.g., 15°/20° head angles of diagonal cutters), fixture replacement requires no tools and can be completed within 15 minutes.
- Automated Docking: Supports integration with existing production lines to realize unmanned loading, improving efficiency by 30%.
- Core Control of Induction Heating
- Equipment: DSP digital series resonant power supply (output frequency: 20–30 kHz) + Siemens PLC S7-1200.
- Parameter Control: Temperature accuracy of ±5℃, power adjustable from 10% to 100%. It monitors heating status in real time and automatically compensates for voltage fluctuations.
- Risk Control: Built-in temperature sensor triggers an immediate shutdown in case of overheating to prevent workpiece burnout.
- Quenching & Cooling System
- Equipment: Combined configuration of plate heat exchanger + water chiller.
- Process: Precise control of quenching fluid flow rate (±0.5 L/min). The cooling rate is matched to material characteristics to eliminate deformation.
- Advantages: No cooling tower required, with a footprint of only 0.8 ㎡ and noise level ≤ 60 dB.
- Inline Inspection Closed Loop
- Equipment: Metallographic analyzer + hardness tester.
- Process: Inspects quenching layer depth (±0.05 mm) and surface hardness. Data is uploaded to the system in real time, and non-conforming products are automatically rejected.
- Value: Reduces rejection rate from 5% to 0.8%.
Revenue data
| Indicator | XK100 Performance | Traditional Equipment Performance | Improvement Amplitude |
|---|---|---|---|
| Energy Consumption Reduction Rate | 40% | – | 40% |
| Single-Piece Processing Time | 15 seconds | 30 seconds | 50% efficiency improvement |
| Hardened Layer Depth Deviation | ±0.05mm | ±0.3mm | 83% precision improvement |
| Defect Rate | 0.8% | 5% | 84% reduction |
| Maintenance Cost | 5,000 CNY/year | 15,000 CNY/year | 67% saving |
Case/Application Scenario
Case Study: Upgrade Record of a Hardware Tool Factory in Guangdong
The factory originally used 2 sets of old-fashioned induction heating machines, with a monthly output of 150,000 pieces, a rejection rate of 6%, and an annual electricity cost of 280,000 yuan. After replacing them with 2 sets of XK100 in 2023:
- Monthly output increased to 220,000 pieces, meeting the demand of overseas orders;
- Rejection rate dropped to 0.7%, reducing monthly losses by 12,000 yuan;
- Annual electricity cost decreased to 168,000 yuan, saving 112,000 yuan.
Applicable Scenarios: Hardware tool factories (mass production), old production line upgrading (domestic replacement), small-batch customization (multi-type pliers), high-precision processing of high-temperature alloys.
