MXPA00003615A - Induction hardening apparatus for a crankshaft - Google Patents

Abstract

An induction hardening apparatus (20) for inductively heating and quench hardening a crankshaft (21) includes an arrangement of two workstations (33, 36) similarly configured and a robotic device (37) indexing the crankshaft from a first workstation to a second workstation. The induction hardening apparatus is designed with a single induction coil (48) located at the first workstation for the sequential induction heating and quench hardening of the pins of the crankshaft. At the second workstation, a single induction coil (63) is used for the bearing surfaces of the crankshaft. One feature of the present invention is that the induction coils do not contact the surfaces of the crankshaft which are being inductively heated and quench hardened. Crankshaft dimensions and geometry are programmed into servodrive systems (49, 51) which move the corresponding coil in X and Y directions accurately tracing the orbit or path of each pin and each bearing surface. Another feature of the present invention is the use of an offset 180 degree coil (310) which provides improved heating patterns in less time than traditional 90 degree coils.

Description

INDUCTION HARDENING DEVICE FOR A CRANKSHAFT REFERENCE TO RELATED APPLICATIONS The present patent application is a continuation patent application in part of the United States patent application serial number 08 / 959,799, filed on October 29, 1997, currently pending.

BACKGROUND OF THE INVENTION The present invention relates generally to methods and apparatuses for inductively heating and hardening a crankshaft with cooling. More specifically, the present invention relates to the inductive heating and cooling hardening of a crankshaft, which can be oriented and either horizontally and vertically, where the induction coil assembly (or assemblies) does not contact the crankshaft. the surface of the crankshaft to be hardened by induction. The computer controlled servomotors and the X and Y drive systems are used to position and move the induction coil assembly relative to a portion of the crankshaft journal according to REF .: 119343 crankshaft rotates at a predetermined RPM. The trip of the induction coil assembly is based on mathematical formulas and the crankshaft geometry, including the dimensions of the crankshaft and the particular location of the portion of the stump to be hardened by induction in relation to the longitudinal axis of the crankshaft. An automotive crankshaft is made up of a series of trunnions, one for each cylinder, in the case of in-line machines, or one for each pair of cylinders, in the case of type-V machines. The function of the crankshaft is to convert the reciprocating movement of the piston and its connecting rod in rotary motion. The crankshaft play is equal to the stroke of the machine. The crankshaft needs to be properly balanced in order to eliminate the centrifugal forces and consequently the crankshaft is counterbalanced by weights placed opposite the corresponding journals or only "spikes". Each pin is received within one end of a corresponding connecting rod whose opposite end is bolted to a piston. The crankshafts are also configured with axial bearing surfaces that are designed for reception by the main bearings. A six-cylinder in-line crankshaft will typically have six main bearings. Due to the load and wear of the pins and on the bearing surfaces, the hardening of these crankshaft portions is important. One approach to this task is to inductively heat and then harden these critical surfaces with cooling. Traditionally, the approach that has been followed is to place the crankshaft in a horizontal orientation and as the crankshaft reaches a substantially elevated temperature due to induction heating, a support member moves in its position in order to support the crankshaft and guard it of buckling. This traditional approach also comprises the induction coil and / or some portion of the contact induction coil assembly, which is actually mounted on the surfaces to be inductively heated and will harden with cooling. This metal-to-metal contact accelerates wear on the coil assembly, necessitating periodic replacement of the coil assembly. The need to replace the induction coil assembly represents not only an additional cost factor, but also a decrease in the time to induction hardening equipment.

By horizontally orienting the crankshaft, contact is actually encouraged by the induction coil assembly on the critical surfaces of the crankshaft, due to the convenience of letting the induction coil assembly "mounted" on the pins and bearing surfaces according to the crankshaft is • rotating between the centers. This traditional approach to making the function of induction coil assembly the same as a follower does not require any separate drive system for the induction coil assembly, since the critical surfaces are in contact with the coil assembly. However, the direct contact between the coil assembly and the portion of the crankshaft that is already to be hardened by induction is seen as a substantial disadvantage, not only due to the wear of the induction coil assembly and the horizontal crankshaft assembly, but also because of the Additional reasons that will be presented later. When the induction coil assembly contacts the pins and / or bearing surfaces, it is difficult to identify the wear condition of the coil assembly. By mounting directly on the crankshaft surfaces, the contact surface of the induction coil assembly is effectively hidden from view, thus making it difficult to assess the level or degree of wear in the coil assembly. This in turn means that the induction coil assembly can run for too long and reach a point at which it arches and this typically ruins the part and ruins to damage the coil assembly. The contact between the coil assembly and the crankshaft frequently results in deterioration or scoring of the crankshaft surface and this requires an extra grinding action which can then be machined in order to rectify the surface imperfections. Then a posthardening step is required, prolonged. It would be a substantial improvement to the present methods and apparatus for induction hardening of the crankshaft, if an apparatus could be provided by the induction coil assembly that does not contact the pins and bearing surfaces. This apparatus would significantly improve the life of the coil assembly. It would also be perceived that it is capable of vertically orienting the crankshaft, which would be advantageous.

While the prior art does not contemplate any suitable solution to the problems that have been identified, the present invention provides an improved method and apparatus that achieves both improvements. According to the present invention, the crankshaft to be hardened by induction can be oriented vertically, although the present invention still works quite well if the crankshaft is oriented horizontally. Additionally, an induction coil assembly for the crankshaft pins is provided which is located and operated in a first work station. A separate induction coil assembly or a series of assemblies are provided for the bearing surfaces and located and operated in a second work station. These coil assemblies are designed such that there is no contact with the surfaces of the crankshaft that the coil assemblies will harden by induction. This improves the life of the coil assembly. In accordance with the present invention, the dimensions and geometry of the crankshaft are used to define the path or orbit of each spigot and the tracking path for each induction coil assembly is computed and programmed into suitable drive systems that control the travel of each coil assembly. While the bearing surfaces also have an orbit, these orbits are concentric with the axis of rotation of the crankshaft. Accordingly, the coil assembly (or assemblies) used for the bearing surface does not have to travel in a mating orbit, but instead they are stationary. The alternative embodiments of the present invention provide design variations to account for the presence of the counterweights or for the presence of any other factors that could affect the balance or balance of the mass (heat balance) adjacent to the crankshaft pins. While there are other designs that suggest a vertical orientation for the work piece, these other designs are limited to camshafts, not crankshafts. There are numerous differences between these two types of drive components, several of which suggest that the technology directed to the camshafts have little relevance to the present invention and the issues that are addressed and solved by the present invention. For example, the individual cams of a camshaft move axially and the protruding ratio of the cam geometry is dimensionally somewhat smaller. Simply, there is no off-axis dimensional change for the cams, which exists for the spindles of a crankshaft. This results in a spike orbit of substantial size and travel relative to any cam orbit that may occur. In turn, this results in substantially different challenges and problems for the design of an induction coil tracking apparatus, suitable with the crankshaft presenting the most challenging design task. With respect to the comparison between a crankshaft and a camshaft, the profile of a stump is symmetrical and requires a uniform, shallow depth. A cam of a camshaft is not symmetrical and requires a uniform, shallow depth. Accordingly, the induction coil assembly does not have to follow a cam and the cam can be induction hardened without having to move the coil assembly in a mating orbit. The desired sleeve depth patterns for the cams can be achieved without the displacement of the induction coil assembly. Minor loads placed on a cam mean that the required hardening depth may be less than that of a crankshaft journal, making induction hardening less demanding. While the present invention can be used for a camshaft, there is no reason to do so. Another characteristic addressed by the present invention is the arrangement of the handling equipment and the cooperative work sensations. In order to provide management efficiencies, the present invention is configured with multiple work stations for loading, induction hardening and unloading of the workpiece in a sequential action. A work station is configured for the induction hardening of the crankshaft journals. Another work station is configured for the induction hardening of the bearing surfaces. These two work stations can be arranged in any order since the dies and pins and the bearing surfaces can be hardened by induction in any order. Since the bearing surfaces are coaxial with the centers supporting the crankshaft, the induction coil assembly for the bearing surface operates in an orbit that is coincident with the axis of rotation (longitudinal axis of the crankshaft). In contrast, the pins that are inductively hardened sequentially, typically one pin at a time, are not located on the shaft and have a different circumferential location, one pin to the next, relative to the position of the crankshaft. While the induction hardening of the crankshafts is known and while the vertical orientation of the camshafts is known, the present invention remains new and not obvious. The combination of the structural characteristics of the present invention provide significant advantages to those currently existing and the need for a long time needed and hitherto unsatisfied by the present invention validates its new advance and not obvious in the art.

BRIEF DESCRIPTION OF THE INVENTION An induction hardening apparatus for inductively heating and cooling hardening a workpiece according to one embodiment of the present invention comprises an attachment for positioning and supporting the workpiece at a workpiece location, a rotary drive unit for rotating the workpiece, an induction hardening station positioned adjacent to the workpiece location and including an induction coil assembly and a positioning system for moving the coil assembly induction in a predetermined path, a control to generate data of the path of the coil based on the geometry and dimensions of a portion of the workpiece to be hardened by induction, the control that is operatively connected to a system of placement and the portion of the work piece that moves in an orbital route during the rotation of the piece of work, wherein the predetermined path, generated by the positioning system, follows the orbital path such that the spacing between the induction coil assembly and the portion of the work piece during the rotation of the workpiece remains substantially uniform, the induction coil assembly that moves to be free of any contact with the portion of the workpiece. An object of the present invention is to provide an improved induction hardening apparatus for a workpiece. The objects and advantages related to the present invention will be apparent from the following description.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is an elevation, side view of an induction hardening apparatus for the crankshaft pins according to a typical embodiment of the present invention. Figure 2 is a plan view of the upper part of the induction hardening apparatus, of Figure 1. Figure 2A in a plan view of the upper part of an induction hardening apparatus according to an alternative embodiment of the present invention. Figure 3 is a front elevational view of the induction hardening apparatus of Figure 1. Figure 3A is a front elevational view of the induction induction apparatus of Figure 2A. Figure 4 is an elevation view, on the right side of the induction hardening apparatus, of Figure 1. Figure 5 is an enlarged, side elevational view of the crankshaft to be hardened by induction by the hardening apparatus. by induction of the 'Figure 1, which includes portions of the coil drive system. Figure 6 is an enlarged top plan view of the induction coil in a first work station comprising a portion of the induction hardening apparatus of Figure 1. Figure 6A is an elevation view, front of the induction coil assembly of Figure 6. Figure 7 is a schematic illustration of the orientation of a crankshaft journal during a revolution of the crankshaft. Figure 7A is a schematic illustration of the orientation of a crankshaft counterweight during a revolution of the crankshaft according to an embodiment of the present invention. Figure 7B is a schematic illustration of the orientation of a crankshaft counterweight and the induction coil assembly during a revolution of the crankshaft according to an embodiment of the present invention. Figure 8 is an elevation, side view of an induction hardening apparatus for the bearing surfaces of a crankshaft according to a typical embodiment of the present invention. Figure 9 is a plan view of the upper part of the induction hardening apparatus of Figure 8. Figure 10 is a front elevational view of the induction hardening apparatus of Figure 8. Figure 11 is a view in elevation, on the right side of the induction hardening apparatus of Figure 8. Figure 12 is an enlarged, lateral, enlarged view of the crankshaft to be hardened by induction by the induction hardening apparatus of Figure 8. Figure 13 is an enlarged, lateral, enlarged view of the crankshaft to be hardened by indiction by the induction hardening apparatus of Figure 8. Figure 14A is an illustration 1 R schematic of an option for the arrangement of the work stations of the present invention. Figure 14B is a schematic illustration of another option for fixing the work stations of the present invention. Figure 14C is a schematic illustration of another option for arranging the work stations of the present invention. Figure 14D is a schematic illustration of another option for arranging the work stations of the present invention. Figure 14E is a schematic illustration of another option to fix the work stations of the present invention. Figure 15 is a plan view of the top and schematic of an induction hardening apparatus according to another embodiment of the present invention. Figure 16 is a front elevational, schematic view of the induction hardening apparatus of Figure 15. Figure 17 is a schematic elevation, side elevational view of the induction hardening apparatus of Figure 15. Figure 18 is a plan view of the upper part of a 90 degree induction hardening coil that is suitable for use with the present invention. Figure 18A is a side elevation view of the induction hardening coil of Figure 18. Figure 19 is a front elevational view of the induction hardening coil of Figure 18. Figure 20 is a view in top plan, schematic, of a 180 degree induction hardening coil, misaligned, according to the present invention. Figure 21 is a side elevational, schematic view of the coil of Figure 20. Figure 22 is a schematic front elevational view of the coil of Figure 20. Figure 23 is a schematic, partial illustration of the The resulting heating pattern in a work piece based on the style of the coil that is used. Figure 24 is a schematic, partial illustration of the resulting heating pattern in a work piece based on the style of the coil that is used.

Figure 25 is a schematic, partial illustration of the resulting heating pattern in a work piece based on the style of the coil that is used. Figure 26 is a front elevational, schematic, partial view of two adjacent pegs or stubs of a vehicle crankshaft having a "spline-slit" design. Figure 27 is a schematic illustration of the misalignment region between the two adjacent pegs of Figure 26. Figure 28 is an elevation, side view of two induction hardening arrangements that include transformers for the use of the two coils of Figure 20. Figure 29 is a side elevational view of the two induction hardening arrangements that include the transformers for the use of the two coils of Figure 20. Figure 30 is an elevation, side view of the two induction hardening arrangements including a co-operating transformer for each that provides the ability to use a coil of Figure 18 and a coil of Figure 20 for the illustrated work piece.

DESCRIPTION OF THE PREFERRED MODALITY For purposes of promoting an endimie or the principles of the invention, reference will now be made to the modality illustrated in the drawings and a specific language will be used to describe the same. However, it will be understood that a limitation to the scope of the invention, such alterations and further modifications to the illustrated device, is not proposed in this way, and these additional applications of the principles of the invention as illustrated herein that are completed as it will normally be presented to one skilled in the art to which the invention relates. With reference to Figures 1, 2, 3, 4, 5, 6, and 6A, an induction hardening apparatus 20 is illustrated which is constructed and arranged to inductively heat and harden a crankshaft 21 with cooling. The crankshaft 21 is placed in a vertical orientation and supported in centers 22 and 23. The illustration of the upper center 22 should be considered as only schematic for the purpose of representing a true vertical orientation for the crankshaft. In real practiceWhen the crankshaft pins are being hardened by induction, a positive lock (clamping press) is required and used. This is illustrated in Figure 5. This crankshaft fixation allows the use of a rotatable drive mechanism, cooperating to rotate the crankshaft, on the axle, between the positive lock (clamping press) and the center. lower 23. Although the crankshaft 21 in Figures 1 and 5 is illustrated in a vertical mounting orientation between the vertical centers, the present invention is equally suitable for a crankshaft that is placed in a substantially horizontal orientation between the hori zontal centers. . Referring continuously to Figure 5, the details of the crankshaft 21 are illustrated. The crankshaft used for an explanation of the present invention includes four cylinder (crankshaft) pins 27a-27d and five cylindrical bearing surfaces 28a-28e. As will be known to one skilled in the art crankshafts, balance weights are placed in cooperative relation to each spike in order to counterbalance the rotation of the spigot and preferably eliminate any net centrifugal force. The pins 27a-27d and the bearing surfaces 28a-28e are arranged in an alternate sequence and represent critical wear surfaces that need to be hardened and the preferred method is by inductive heating and cooling hardening of these critical portions of the crankshaft. This is the role of apparatus 20 that is constructed and arranged to sequentially place an induction coil assembly adjacent to each peg 27a-27d and perform the required heat treatment steps. The bearing surfaces 28a-28e are inductively heated and harden by cooling in another work station which in an embodiment of the present invention comprise other portion of the apparatus 20. In one embodiment of the present invention (see figure 6A), the capacity Cooling with water is installed in the induction coil assemblies that are used for the bearing surface pins. In another embodiment, the cooling step is performed by a separate cooling station that is not installed in the coil assembly. In accordance with the present invention, there are actually three primary configurations for the apparatus 20 with a secondary variable for each primary configuration. In the illustrations of Figures 1-4, the apparatus 20 includes two work stations, virtually identical, both of which are designed for induction hardening of the pins. This configuration allows two crankshafts to be induction hardened simultaneously in a side-by-side arrangement. A second apparatus 30 (see Figures 8-11) is provided for the induction hardening of the crankshaft bearing surfaces. The apparatus 30 used for the bearing surfaces can be used before the use of the apparatus 20 or subsequent to the use of the apparatus 20. The sequence of the induction hardening as between the pegs and the bearing surfaces is not critical. However, if multiple bearing surfaces are induction-hardened simultaneously, a post-timed operation may be desirable in order to eliminate any minor distortion and put the crankshaft back to tolerance. The apparatus 30 is constructed and arranged with two virtually identical working extractions, like the apparatus 20, and in this way two crankshafts can be processed in a side-by-side manner at the same time. A second primary configuration of the present invention includes a design for the apparatus 20 that includes only one (1) work station that is constructed and arranged for induction hardening of the spikes. In a similar manner, the apparatus 30 is constructed and arranged with only one work station for the induction hardening of the bearing surfaces. These two individual workstation devices can be used in any order and do not need to be used in close proximity to each other. Conceivably, as a minor modification to this second primary configuration, it is contemplated that an apparatus with a plurality of work stations will be fixed and the other apparatus will be fixed with only one workstation. The third primary configuration of the present invention includes a design for the apparatus 20 where there are two work stations, but one work station is used for the crankshaft pins and the other work station is used for the crankshaft bearing surfaces. This side-by-side arrangement of the two work stations, where each is dedicated to a different portion of the crankshaft, can be advantageous in smaller workshops with more limited runs.

There are several combinations of apparatus and work station for the present invention and while some of the combinations have been mentioned, further combinations are illustrated in Figures 14A-14E. As a partial compilation of the above descriptions, Figure 14A schematically illustrates two apparatuses 20 and 30 each with two work stations 33 and 36 and 46 and 47, respectively. Work stations 33 and 36 are constructed and arranged for induction hardening of the crankshaft pins. Work stations 46 and 47 are constructed and arranged for induction hardening of the bearing surfaces of the crankshaft. Figure 14B schematically illustrates the use of two virtually identical apparatuses 200 and 300. Each apparatus excludes a spike work station (33, 36) and a bearing surface work station (46, 47). In Figure 14C, an individual apparatus 200 is used, and in this way it should be understood that the number of apparatuses can be varied, the number of work stations in each apparatus can be varied, and the particular style of the work station in each device it can be varied. Figure 15D schematically illustrates two separate apparatuses 201 and 301, each of which includes an individual work station, a work station 33 for the spikes and the other work station 46 for the bearing surfaces. In Figure 15E, apparatuses 120 and 130 are illustrated schematically and in this arrangement, work stations 133 and 136 are constructed and arranged for induction heating of the two (or more) spikes, in a simultaneous manner. Apparatus 120 is illustrated in detail in Figures 2A and 3A, but it is mentioned that in order to cover a further variation of the present invention. Also, it is to be understood that work stations 46 and 47 are constructed and arranged for induction hardening of multiple bearing surfaces in a simultaneous manner, typically either two at a time or three at a time, see Figures 12 and 13. In addition, it is to be understood that multi-spike work stations 133, 136 may be replaced by work stations 33 and / or 36, respectively, in any of the arrangements of Figures 14A-14D. In Figures 15, 16 and 17 a further combination of the features of the present invention is illustrated, where an individual work station is constructed, and arranged to inductively harden both spikes and bearing surfaces. An individual coil assembly is used for the dowels and two bobbin assembly assemblies are used for the bearing surfaces, similar to what is described in Figures 12 and 13. There is a vertical, individual positioning system, and indeed , an individual spindle which is common to the three series or coil assembly assemblies which are placed by means of the positioning mechanisms on the axis of the X and on the axis of the Y. As an embodiment of the present invention it is mainly aimed at the design of the induction coil assembly and the drive systems that allow the coil assembly to accurately track the orbit of each peg of the crankshaft workpiece, there are other design features of the apparatus 20 which they are of importance, including the associated equipment, placement of the crankshaft workpiece, the design of the work stations, and the automated nature of the complete apparatus. Additional embodiments of the present invention provide variations in the rotational speed of the crankshaft and the travel speed of the coil assembly during an individual cycle (i.e., revolution), variations in the power supply output, and the shape of the travel path of the coil assembly. What is important to understand with respect to the first embodiment of the present invention is that as the crankshaft is rotated in a vertical orientation in an inner center, each of the pins and each of the bearings generate a particular orbit or travel route. When a coil assembly is placed adjacent a particular spike for inductive heating and quench hardening, the coil assembly moves in an X / Y direction to follow or trace the same orbit without contacting any portion of the crankshaft. In another, related embodiment of the present invention, it changes, accelerates and / or decelerates the speed of rotation of the crankshaft, and consequently, the travel speed of the tracking coil assembly, during each cycle, in order to adjust or accommodate the thermal loss due to counterweights. In still further embodiments of the present invention, the orbit or tracking path of the coil assembly is designed to change the spacing between the coil portion of the coil assembly and the crankshaft pin to adjust the heat loss due to the presence of the counterweights and thus achieve a uniformity in the depth of the shirt. The adjustment for the heat loss of the counterweights can also be achieved by rapidly changing the kW output of the power supply. While reference is made to the thermal loss caused by the counterweights, the corresponding adjustments represented by the alternative modalities can be practiced, if there is a structure or any other reason that affects the mass balance (thermal equilibrium) adjacent to the spikes ( or spike) of the crankshaft. Additionally, if the bearing surfaces that are coaxial with the longitudinal axis of rotation of the crankshaft include some type of heat sink or thermal variable then adjustments can be made to decompensate or compensate for any thermal loss of the selected surface for induction hardening. If the corresponding induction coil remains stationary, the thermal loss adjustment forms for the bearing surfaces include a speed adjustment when accelerating and decelerating and a power output adjustment by varying the output power of the coil assembly, depending of the position of the heat sink or thermal loss structure component. The description of these two settings for the pins is schematically depicted in Figure 7A. When the bearing surfaces are comprised in place of the pins, the coil assembly 63 is placed around the corresponding bearing surface, such as the bearing surface 28a. It should be noted that the spool assembly 48 is for the spikes, while the spool assembly 63 is used for the bearing surfaces. With the coil assembly 63 positioned in this way, speed adjustment and adjustment of the power output for the bearing surfaces of the same are made that these adjustments for the pins were made. If the induction coil assembly 63 is allowed to change in the direction of the Y axis (only), then the coil assembly positioning adjustment (see Figure 7B), which is an option for the spikes, can be used to the bearing surfaces. Here again, the coil assembly 63 is placed around the bearing surface such as the bearing surfaces 28A and the coil assembly moves in and out (Y axis direction) in order to change the spacing between the surface inside the coil portion and the bearing surfaces. The closer the inner surface is to the bearing surface, the greater the amount of heat generated in the bearing surface. With continuous reference to the first embodiment, by accurately introducing the dimensional and positional data in a servo-drive system, the present invention moves the induction coil assembly in a manner to maintain substantially uniform the spacing between the interior surface of the coil assembly and the outer surface of the particular spigot. Because the bearing surfaces are coaxial with the vertical centers, the "orbit" of each bearing surface is on the axis of all the orbits of the bearing surfaces are the same. Accordingly, the induction coil assemblies of the present invention as well as the coil positioning systems are described as "contact free" because they do not contact the surfaces of the crankshaft to be induction hardened. With respect to Figures 1, 2, 3 and 4, Figure 2 is a plan view of the upper, complete part of the apparatus 20. The remaining Figures each have some portion removed for clarity of the drawing. In Figure 1, the portions of the controls, frame and drive use have been removed for clarity of drawing. In Figure 3, the crankshaft, system components, and robot have been removed for clarity of the drawing, while in Figure 4, the human / machine interface (HMI) has been removed. Consequently, these four Figures should be considered together as a complementary set. Based on the illustrations of these Drawing figures, the induction hardening apparatus 20 includes a first work station 33 located within a confinement 34 with front side access doors 35 and a second work station 36 of a similar construction. The two work stations are illustrated with closed doors, but with arms, centers, drive units and illustrated bearings. Therefore, Figure 3 should be considered as schematic with respect to that illustrated behind the closed couplings 35. In the first work station, the pins or taps 27a and 27d of a first crankshaft are inductively heated and hardened by cooling. In one embodiment, an individual coil is used and the pins are induction hardened sequentially. In a related embodiment, see Figures 2A and 3A, two pins are allowed to harden by induction simultaneously. This requires the use of two coil assemblies and a design by which the pins 27a and 27c are induction hardened together and then subsequently the pins 27b and 27d are induction hardened together (i.e., simultaneously). In the second work station 36, the pins of a second crankshaft are heated inductively and harden by cooling. In essence the two work stations 33 and 36 are of virtually identical construction and are used concurrently to inductively harden two separate crankshafts. The crankshafts in the two work stations have not been illustrated in Figure 3 for clarity of the drawing. The two crankshafts hardening by induction in the two work stations 33 and 36 are loaded and unloaded by means of the robot 37. If the second apparatus 30 is present for the induction hardening of the bearing surfaces of the two crankshafts, then the crankshafts are also moved to the bearing surface apparatus 30 by a robot mechanism such as the robot 37. In this second apparatus location, the bearing surfaces 28a-28e are inductively heated and harden by cooling. When it is finished, the robot 37 removes the crankshafts and loads the next crankshafts into position in the first apparatus. With continued reference to Figures 2 and 3, the processing of the crankshaft 21 to the work station 33 will be described in detail. It should be understood that the structure of the work station 36 is virtually identical when induction hardening the pins of a second crankshaft. The crankshaft 21 moves in its position in the work station 33 of the apparatus 20 and is held in the vertical orientation, desired by a robot arm until the support arms 40 and 41 in the first work station 33 (and arms of support 42 and 43 in the second work station 36) are taken on the vertical positioning and support of the crankshaft 21. Each support arm 40-43 is automatically moved in its position based on a set of control circuits, logic , programmable used to pre-program the mechanical drive systems and servomotors associated with each support arm. Each lower support arm 41 and 43 is mounted with a centering spindle tip 41a and 43a, respectively, for insertion into a corresponding central plug at the end of the crankshaft which is loaded in its position at the corresponding work station. The upper support arms 40 and 42 are each mounted with a bearing housing 40a and 42a, respectively, and a cooperating clamping press 40b and 42b, respectively, which is used to secure the upper end of the crankshaft. The fixing of the crankshaft in this way maintains a vertical, true orientation and provides a true vertical axis for the rotation of the crankshaft in its center line, longitudinal which is concentric with the axis and the central, geometric line of each bearing surface 28a, 28e cylindrical While the axial position of each upper arm 40 and 42 during the steps of inductive heating and hardening by cooling is the same for each crankshaft, in spite of the size and length, the lower arms 41 and 43 can be moved and changed axially to different "run" positions in order to adjust the different lengths of the crankshafts. Mounted on the end of the lower arm 40 is a spindle motor, of electric current 44 for rotating the crankshaft at a predetermined speed. A similar electric current spindle motor 45 is mounted on the end of the upper arm 42 to rotate by rotation in the second work station. The rotation of the crankshaft is generally beneficial in order to make a uniform and balanced heating pattern in the workpiece, if the portion can be the focus of the induction hardening. The rotation of the crankshaft is also beneficial for uniform cooling. Since the induction coil assembly used in each work station of each apparatus as part of the present invention has an open semi-cylindrical shape, it is essential that each crankshaft be rotated in order to obtain complete and uniform heating of the portions crankshaft reviews. In the first apparatus 20, including both work stations 33 and 36, these critical portions are the pins 27a-27d. In the second apparatus 30, which includes both work stations 46 and 47, these critical portions are the bearing surfaces 28a-28e. The following description relating to the first work station 33 is virtually identical for the second work station 36. The upper arm 40 is connected to a clamping cylinder 33a (cylinder 36a in work station 36) which is used for fastening the corresponding crankshaft between the clamping press 40b and the centering spindle tip 41a. The vertical movement of the clamped and centered crankshaft comprises the vertical positioning portion 33b (portion 36b in the work station 36) that provides the driving unit of the Z axis. This drive unit of the Z axis is a servo unit - ball screw drive and used to change the vertical position of the crankshaft when desired to move the crankshaft so that a different pin is placed, adjacent to the corresponding induction coil assembly. In one embodiment of the present invention, an individual induction coil assembly 48 is located on the first work station 33 is securely mounted to a Y-drive system 49 which is controlled by a set of servo circuits, suitable, based in part on the geometry and dimensions that are derived from the crankshaft drawings or elsewhere from the specifications. The system 49 is constructed and arranged to move the induction coil assembly 48 in and out of the direction of the arrow 50. The coil assembly 48 is also securely mounted to an X drive system 51 that is controlled by the servo-drive circuitry that is programmed in a manner similar to that used for the Y-drive system 49. The system 51 is constructed and arranged to move the induction coil assembly 48 side by side in the direction of the arrow 52. The drive systems 51 and 49 in X and Y each incorporate ball screw servo-tables that accurately place the induction coil assembly 48. These two tables are mechanically connected to each other with a ratio of ninety (90) degrees or right angle as will be understood and expected for the drive units of X and Y. As explained, the crankshaft 51 is in effect mounted in the centers 22 and 23 and it is rotated. In actual practice, the upper center 22 takes the form of a clamping press 40b. A servomotor (spindle motor, electric current) 44 is used to drive the crankshaft and provide the rotation data and the position data of the pins to a computer control which is operably connected to the systems 51 and 49 of drive in X and Y. The location data with respect to the position of the corresponding pin or stump 27a which is to be inductively heated and hardened with cooling are fed into the computer control which uses a database program to move the induction coil assembly 48 into a tracking orbit that follows the particular orbit for the particular spike. The computer control program controls the X and Y drive systems and specifically the corresponding ball screw servo-tables, which place the coil assembly. Each spike has a circumferential location, particularly in relation to the longitudinal axis of the crankshaft 21. These pin locations coincide with the firing frequency for the cylinders of the machine. While the orbit of each spike is circular and as each orbit is of the same size, the actual location of a particular spike within its circular orbit at any instant of time depends on which spike is being considered and the corresponding cylinder. Accordingly, since the servomotor 44 provides position data with respect to the rotational state of the crankshaft, it is possible to compute a precise and corresponding location of the pin for each crankshaft pin 27a-27d, since the dimensions and angularity of the pin are they know from the specifications and the detailed crankshaft action programs or CAD drawings. With this data, it is thus possible to create an orbital tracking path for the induction coil assembly 48 relative to each spike. In the first embodiment of the present invention, the drive systems for the induction coil assembly are programmed to move the coil assembly into an orbit or path that precisely traces or copies the orbital path of the pin which is being hardened by induction . This precise tracking by the coil assembly places the inside surface semidircular of the coil portion to a fixed gap of separation (see Figure 7) in relation to the surface of the outer diameter of the spike.

According to the present invention, the induction coil portion of the coil assembly 48 has a semi-cylindrical shape of a circular part (see Figure 6). The inner surface 57 is formed to correspond to the shape of each crankshaft pin that is cylindrical. By creating the coil assembly 48 with an open side, the coil is able to fit around a portion of each crankshaft. As the particular spindle rotates with the crankshaft, its entire circumference is finally placed directly adjacent to the inner surface 57. This positional relationship is illustrated schematically in Figure 7. Four points A, B, C and D located at ninety (90) degrees have been identified on the surface of the cylindrical pin 58 in order to be able to show how these points change in relation to the X and Y directions for the induction coil assembly 48 as represented by the arrows 52 and 50, respectively. The description of what occurs in the first work station 33 of the apparatus 20 is duplicated in the second work station 36 of the apparatus 20 when the second work station is configured to inductively harden the spikes. In those situations where the counterweights are used and connected adjacent to the dowels, there is a heat sink that removes heat away from the dowel where the coil assembly is giving the portion of the dowel that is closest to the counterweight. As will be understood for an induction hardening apparatus of the type described herein, the heated portion of the pin, bearing surface, is located and that portion is closest to the interior, semi-solid surface 57 of the coil portion. Consequently, when the coil portion is opposite the counterweight, there is no perceptible loss of the heat sink that needs to be addressed by some shape adjustment. In the related embodiments of the present invention, the adjustment form to compensate for heat loss takes three different forms. In an embodiment of the present invention (see Figure 7A), the crankshaft rotation (accelerate and / or decelerate) is varied in each revolution so that there is a brief residence or boost of the rotation speed when the coil portion is adjacent to the portion of the heatsink ( that is, counterweight 58a) of the spike. This residence generates more heat that compensates for the heat that is lost due to the mass of the counterweights that conduct the heat away from the subdued area. In the drawing of Figure 7A, location of the counterweight 58a in relation to the coil assembly 48 is illustrated in four different positions (Z0-Z3) during a cycle corresponding to a revolution of the crankshaft. As described, the rotational speed (SR) of the crankshaft is varied depending on the location of the counterweight (ZN) relative to the coil portion of the coil assembly. The coil assembly 48 is illustrated schematically by a coil portion, semi-cylindrical. In the position Zl, when the coil portion is effectively centered in the counterweight 58a, the rotation speed (SR?) Will be the minimum of the complete cycle. This causes the coil portion to remain adjacent to this portion of the coil for a longer interval so that more heat is introduced into the spike. When the coil portion and the counterweight 58a are on opposite sides of the peg 58, the position Z3, the rotation speed (SR3) is at the maximum of the cycle (i.e., one revolution for the crankshaft). This means that the heating interval will be somewhat shorter which is appropriate because the counterweight 58a is not going to remove any significant amount of heat from the spike. Between these two extremes of speed, the speed of rotation accelerates and decelerates. The acceleration line from Zl to Z3 coincides with the deceleration line from Z3 to Zl. In another embodiment of the present invention, (see Figure 7B), the distance of the spool assembly from the spacing relative to the spigot surface varies or changes slightly during each cycle (ie, each revolution of the crankshaft). When the coil assembly is on the counterweight side of the pin, it is placed closer to the pin when the counterweight is on the opposite side of the coil pin. By placing the coil portion closer, the heat generated by the coil assembly in the spike is greater than the closest distance. This approach requires that the X and Y drive systems for the coil assembly be controlled to sweep a route that is more electrical than circular. In the drawing of Figure 7B, the location of the counterweight 58a relative to the coil assembly 48 is listed in four different positions (Z0-Z3) during one cycle. The positions of Figure 7B correspond in general to the positions of Figure 7A. In the Zl position, the coil portion is in something closer to the spike that generates the most heat that compensates for the heat that is lost due to the counterweight that acts as a heat sink. In the position Z3 which is 180 ° from the position Zl, the coil portion is at its location of greatest separation from the spike. This is the position where the counterweight has less effect, if any, on the thermal reduction due to the counterweight that acts as a heat sink. As the spindle crankshaft 58 rotates through the position of Z2 from Z1 to Z3, the distance between the inner surface 57 of the coil portion and the outside diameter surface of the spike increases. Then, when you return from Z3 to Zl through position Z0, the separation distance decreases. If a point (X) is marked on the coil portion and its route is plotted for a cycle, it will be seen that the tracking orbit is elliptical rather than circular. In still a further embodiment of the present invention, the path of the coil portion of the coil assembly is circular, the rotation speed is constant, and the separation distance remains constant, however, the power output (kW) of The power supply for the coil assembly is varied depending on the position of the crankshaft accordingly depending on where the coil portion is positioned relative to the orientation of the spigot and the location of the counterweight. The drawing of Figure 7A is suitable for schematically illustrating the rotation of the pin and the counterweight when the power output is varied. In the Zl position, the power or energy output is the largest due to the location of the counterweight. In position Z3, the power output is the lowest due to the location of the counterweight. The power output decreases from Zl to Z3 and then increases from Z3 to Zl. Whenever the coil is adjacent to the counterweight side of the spike, the power output is increased to generate more heat and thereby compensate for the heat that is lost via the counterweight. It is important to understand that the adjustments made by these alternative modalities will all be achieved with the same mechanical and electrical structures associated with the apparatus 20. All the adjustments are made by changing the speed programming of the spindle motor and the speed of the motor. tracking of the X and Y drive systems, by changing the trip in X and Y to vary the spacing or by changing the power output of the power or energy supply. An important feature of the present invention is that the induction coil assembly is free from any direct physical contact with the crankshaft pin which is inductively heating and hardening with cooling. The induction coil assembly is also free of any direct physical contact with all other orbiting characteristics. likewise, the second apparatus, the corresponding induction coil assembly is free from any direct physical contact with the crankshaft bearing surface which is being inductively heated and hardened with cooling, this lack of any contact includes the lack of any sensor or position indicator that is mounted on the surface of the corresponding spigot or bearing surface. In this way, the coil assembly is not subjected to wear, which would otherwise reduce to significantly shorten the life of the coil. By designing an apparatus where there is no contact between the coil portion of the assembly and the surface or portion that hardens by induction, the wear of the coil portion is virtually eliminated and the life of the coil portion is greatly extended. Also, since all the other portions of the induction coil assembly are free of any contact with the crankshaft portion which hardens by induction, there is no wear to these portions and there is no shortened life. Some of the keys to the success of the present invention include the precise programming of the movement of X and Y in the coil, based on the orbit of the spike and the semicylindrical, open design of the coil portion of the coil assembly. While a vertical crankshaft orientation is preferred, the adequacy of the present invention is not limited to a vertical crankshaft. The present invention performs equally well for crankshafts that are supported horizontally between the centers. The first work station 33 which has been described in relation to the coil assembly trip and the induction hardening of the crankshaft pins has a design which is eventually duplicated by the second work station. The second workstation 36 includes a virtually identical X drive system 61, a virtually identical Y drive system 62, the cooperating ball screw servo-table adjusts ninety (90) degrees to each other, and an induction coil assembly 63 with the semi-cylindrical, open configuration, which is virtually identical to the coil assembly 48. The servo motor 45 operates in a manner virtually identical to the motor 44 and controls the rotational movement of the corresponding crankshaft. As described, the two work stations 33 and 36 of the apparatus 20 are constructed and arranged to be virtually identical, so that two crankshafts can be processed concurrently, thus duplicating the speed of performance. When both work extensions 33 and 36 are designed for the induction hardening of the crankshaft pins, their construction is virtually identical, so that the crankshafts can be processed in a concurrent manner. The main difference between the first apparatus 20 and the second apparatus 30 is the difference between those crankshaft portions that induction harden at each apparatus location. In the first apparatus 20, the crankshaft pins are hardening by induction, while in the second apparatus (see Figures 8-11) the bearing surfaces are those which are being hardened by induction. Since the cylindrical bearing surfaces are coaxial with each other, are of the same cylindrical size, and are centered on the longitudinal axis of the crankshaft, the movement control of the 64a-64e assemblies of the induction coil of the bearing surfaces is less complex in the second apparatus 30. The above comparison is applicable if these apparatuses include one, two or more different numbers of virtually identical workstations. With respect to the bearing surfaces 28a-28e comprising a portion of the crankshaft 65, these surfaces, as indicated, have substantially the same outer diameter and cylindrical shape. Importantly, these cylindrical surfaces are concentric with the longitudinal axis of the crankshaft and therefore concentric with the longitudinal axis extending between the two support centers. As illustrated, the upper center is preferably replaced with a positive lock (clamping press). In consecuense, because the bearing surface does not really have its own unique orbit, the induction coil mounts 64a-64e used in the work stations of the second apparatus 30 have a fixed position during the rotation of the crankshaft, once each assembly The coil is initially adjusted in its intended vicinity to the corresponding bearing surface. There is still a need for some type of X and Y placement system to initially place each coil assembly adjacent to the corresponding bearing surface, but once it is properly positioned, the induction coil assembly for the surfaces of Corresponding bearing does not have to be moved or plotted on a particular or corresponding orbital route. This is obviously different for the spikes due to their off-axis location relative to the center line of the crankshaft. To the extent that the crankshaft 65 can accept the amount of heat that is generated without more than one bearing surface being heated inductively and simultaneously, it is possible to use a plurality of coil assemblies 64a-64e in the work stations of the apparatus 30 The configuration of the apparatus 30, as illustrated in Figures 8-11, includes a series of five induction coil assemblies 64a, 64b, 64c, 6d and 64e. The crankshaft 65 which is loaded in position between the vertical centers 66a and 66b includes five bearing surfaces and the operation of the apparatus 30 inductively heats three of the five bearing surfaces in one operational cycle and the two remaining bearing surfaces in a separate operational cycle (see Figures 12 and 13). As described, the upper center 66a is preferably a positive securing press (holding press) of the style of the holding press 40b. Each step of induction heating is followed immediately by a cooling step. Consistent with the above descriptions, the cooling fluid is distributed by means of the induction coils in one embodiment of the present invention. In an alternative embodiment, the cooling fluid is distributed by a separate cooling mechanism, which does not use the induction coil assemblies as a distribution device.

In the illustration of Figure 8, the five coil assemblies 64a-64e are each illustrated as being positioned relative to their corresponding bearing surfaces of the crankshaft 65. This arrangement will be used if the five bearing surfaces were to be hardened by induction simultaneously. However, since this would generate too much heat, Figures 12 and 13 illustrate how the three coil assemblies are used first and then how the two coil assemblies are used. The order can be reversed, but the point is that by simultaneously heating a smaller number of bearing surfaces, there is less heat generated and less distortion. If the two bearing surfaces are inductively heated and harden with cooling before or after the other three bearing surfaces, the simultaneous processing of multiple bearing surfaces results in a complete, faster completion cycle compared to the processing of the bearing. one bearing surface at a time. Included as part of the apparatus 30 is an inductive power supply 30a, a system 30b for driving the Y-axis, a sliding rail 30c, a transformer assembly 30d, a common bar 30e and the common bar extension 30f. With the exception of the common bar extension and the sliding rail that replaces the drive system 51 of the X axis of the apparatus 20, the apparatus 30 is virtually identical to the apparatus 20. Referring now to Figs. 15, 16 and 17 a further embodiment of the present invention is schematically illustrated. The apparatus 220 includes three horizontal positioning systems 221, 222 and 223, each of which is connected to a corresponding coil assembly for the pegs or to a plurality of coil assemblies for the bearing surfaces. With the placement system includes the placement systems of the X axis and the axis of the Y that fix each other at a 90 degree angle. For the bearing surfaces (systems 221 and 222), the X axis positioning system is a manual sliding device. It has also illustrated that there is a separate thermal station transformer 224, 225 and 226 located adjacent to each horizontal position system. The apparatus 220 includes all the normal system components, although these are not illustrated. These normal system components are illustrated in other Drawing Figures and are excluded here simply for clarity of drawing and due to the fact that the focus of the embodiment of Figures 15-17 is otherwise the combination in their hardening systems by induction of individual workstation for both spikes and bearing surfaces. The apparatus 220 further includes a common support system 227 for vertical travel to the elongate of the Z axis, a clamping press 228 and a vertical, lower, support center 229. In the illustrated embodiment of Figure 15, if the three horizontal positioning systems 221, 222 and 223 are actually used, the common sport system 227 (or conceivably one of the horizontal positioning systems) needs to be hinged outside. of its illustrated position in order to be able to load the workpiece (ie crankshaft) in its position. Another option is to load the work piece from the top (ie, at the top). Another option is to use only two of the three horizontal placement systems and as a way to illustrate this option, the 222 system is sketched with a dashed line in Figure 15. While some of the components and features have been removed in some of the drawings simply by the clarity of the drawing, a complete understanding of the apparatus 220 can be achieved by the following analysis. The construction of the apparatus 220 can be seen upon perceiving that the positioning system 221 and the transformer 224 are substantially the same as those illustrated in Figure 12 which controls three coil assemblies which are used to simultaneously inductively harden three surfaces of bearing. The positioning system 222 and transformer 225 are substantially the same, those illustrated in Figure 13 that control the coil assemblies that are used to simultaneously inductively harden two bearing surfaces. The positioning system 223 and the transformer 226 are substantially the same as those illustrated in Figure 5 that control a coil assembly that is used to sequentially induce the pins of the signage 230. The coil assemblies include the assemblies 221a , 221b and 221c for system 221, assemblies 222a and 222b for system 222, and assembly 223a for system 223. In Figure 16, bearing surface coils 221a, 221b, 221c, 222a and 222b do not neither is the positioning system 223 illustrated. In Figure 17, the positioning system 223 is illustrated, but the two bearing surface positioning systems 221 and 222 are omitted for clarity of the drawing. The support arms 231 and 232 are configured the same as the arms 40-43 as would be expected consistent with the description of Figures 15-17. In all aspects of the operation of the apparatus 220 it is the same as in the operation of the corresponding portions of the apparatuses 20 and 30. The differences include the use of a vertical, individual positioning system for the crankshaft in combination with the systems of horizontal positioning (sliding) that place the bobbins for both pins of bearing surfaces in the same individual work station. It is also an option with the present invention to configure the apparatus 20 and work stations 33 and 36 with multiple induction coil assemblies, each with its own servo drive system, its own X and Y drive systems, and its set of control circuits. This allows simultaneous processing of the multiple pins of a crankshaft. If the two work stations are configured and used as part of the apparatus 20, then each work station can be configured with multiple induction coil assemblies for the crankshaft pins. Referring now to Figures 2A and 3A, the apparatus 120 is illustrated with the work stations 133 and 136. In view of the fact that the apparatus 120 is virtually identical to the apparatus 20, although the addition of a second coil assembly and the cooperating driving systems, the corresponding reference numbers have been given with a prefix of number 100. Accordingly, the work station 133 is proposed to be virtually identical to the work station 33 and similarly the work station 136 is proposed to be virtually identical to the work station 36. One of the differences between the apparatus 20 and the apparatus 120 includes the relocation of the vertical position portions 133b and 136b (33b and 36b for the two work stations). work 33 and 36), respectively, to the space between the two work stations 133 and 136. This makes the left side of a work station 133 and the right side of the other work station 136 ab They are so arranged that they can be installed by receiving function systems of X and Y 151a and 149a and 161a and 162a, respectively, as illustrated in Figures 2A and 3A-. The second drive arrangement of XY at workstation 133 is virtually identical to the arrangement of the X 151 voltage system of the drive system of Y 149. Similarly, the second drive arrangement XY of workstation 136 is virtually identical to the arrangement of the drive system of X 161 of the drive system Y 162. With respect to the four driving arrangements XY that are illustrated, each one includes a drive system of the X axis, a driving system of the shaft of the And, a transformer, and a transformer housing. In order to illustrate all these component parts, the drawings have been adjusted schematically to remove the transformer from the two locations to better show the drive units of X and Y. Likewise, the first X-Y drive arrangement located in the work section 133, the second drive arrangement X-Y is connected to an induction coil assembly 148a via a common bar 181a and a quick change device 180a. The first X-Y drive arrangement is connected to the coil assembly 148 via a common bar 181 and the quick-change device 180. By providing a second induction coil assembly 148a with all cooperating structures and drive systems, at each work station, two pins can be induction hardened simultaneously. If, when distributing the heat, the pins 27a and 27c (first and third pins) harden by induction during the first cycle. Subsequently, the pins 27b and 27d (2a and 4a pins) harden by induction during the second cycle. By tripling the assembly number of induction coils, the time of the induction hardening cycle for the crankshaft pins is able to be cut in half. This can be achieved by varying the power during the cycle. If the speed is varied, then the counterweights must be synchronized to the positions of both coils. This may not be possible for crankshafts. The additional components and systems illustrated in Figures 2A and 3A having counterweights in Figures 1, 2, 3, 4, 5 and 6 include human / machine interface 175, induction mounts 163 and 163a, gates 135, of enclosure 173, transformer 172, transformer housing 172a and enclosure 134. Depending on the specific design of the crankshaft and the various cycle times, the use of multiple coil assemblies at each work station and the use of multiple stations Work may be more advantageous for some crankshaft designs than for others. The design planning of each device, including the number of work stations and the design of each work station, must be done with an appreciation of the type of crankshafts to be run, so that the cycle operation of the crankshaft from appliance to appliance is efficient and effective and profitable. Another factor to consider are the tolerances that are going to be maintained. If a plurality of bearing surfaces are induction hardened simultaneously, there could be some slight distortion that requires the subsequent grinding operation. There is no question of distortion when only one spike at a time hardens inductively. For this reason, it may be desired to terminate the induction hardening of all bearing surfaces and bring the crankshaft back into tolerance before initiating the induction hardening of the crankshaft pins. With continued reference to Figures 1, 2, 3, 4, 5 and 6, some of the normal system components associated with each apparatus are illustrated. The induction hardening apparatus 20 includes for the first and second work station 33 an inductive power supply 67 of 300kW / 10kHz and a second precision horizontal slide, composite 68 which provides the driving systems of X and Y 51 and 49 , respectively. Duplicate equipment is provided for the second workstation 36 including the inductive power supply 69 and the horizontal slider 70. The slider or carriage 70 provides a drive systems X and Y 61 and 62. Each workstation 33 and 36 they also include transformation of heat station 72 and a transformer housing 72a. Enclosures 34 and 73 are provided to enclose the crankshafts and coils at each work station. The apparatus 20 includes certain components and systems that interact with both work stations including the human / machine interface 75, various pneumatic apparatuses and controls 76, a main control enclosure 77, positioning control enclosure 77a and a fluid system 78. Also included is the cooling filter 79, a quick change device 80 for each coil assembly, and the common bar 81. The main control enclosure 77 includes the PLC controls computer., set of logic circuits, run controls, switches and sets of input and output circuits for the device. The enclosure 77a includes a circuitry for positioning control devices. With specific reference to Figure 2, a 800 gallon cooling water tank 82 is coupled for flow to two 15 HP 83 and 84 cooling pumps. The pump 83 is coupled with a flow line to the first work station 33 while the pump 84 is coupled to the second work station 36. The return lines 85 and 86 return the cooling water that is used in each work station and is collected back into the cooling water tank 82. The 87 distilled water tank contains a distilled water supply for the cooling of the electrical components. Pump 88 is used to distribute distilled water from tank 87. Pump 89 is a recirculation pump for cooling purposes only. Each induction coil assembly 48 and 63, of one embodiment of the present invention, is configured with a series of flow openings placed around its inner surface for rapid distribution of the cooling water to the inductively heated portions of the crankshaft, if These portions are included to a pin or bearing surface (see Figure 6A). When configuring the coil assemblies with a cooling capacity, there is no need to move the induction coil assembly and either place the crankshaft in each cooling station or move a separate cooling system into position. The combination of the steps of inductive heating and hardening with cooling in the individual coil assembly is an option for the present invention. Additionally, the use of a separate cooling system is terminated as a very viable part of the present invention due to the availability of excellent cooling system technology. The use of a separate cooling system is beneficial whenever the design of the coil assembly is going to be simplified or where there is a desire to shorten the cycle time.

As described, the cooling capacity or function is realized in one embodiment of the present invention by flow holes machined directly in the induction coil assembly. These flow holes are connected to the flow lines that are connected to the corresponding cooling pump, see Figure 2. The alternative mode when a separate cooling mechanism is used, the same flow lines are connected in the cooling mechanism. Cooling The actual cooling step is preferably carried out in stages. The first stage is while the crankshaft is still rotating immediately after the spigot or bearing surface has been raised to the desired temperature. When a secondary or complementary cooling is carried out, this occurs in a location different from the axis of the Z that requires a vertical change of the crankshaft. While complementary cooling is being performed, the next spike is capable of being positioned relative to the induction coil assembly for processing. This duplication of different functions helps reduce the total cycle time for the crankshaft. The system trace of Figure 2 for apparatus 20 is virtually duplicated by the system trace for apparatus 30 as illustrated in Figure 9. Accordingly, the same reference numbers have been used in order to identify components and / or subsystems that are virtually identical in the apparatuses 20 and 30. The main difference between the apparatuses 20 and 30 is in the drive systems of X and Y due to the induction hardening of the pins via the induction hardening apparatus 20 of the bearing surfaces via the device 30. With an individual coil assembly at each work station, the steps of inductive heating and hardening with cooling are sequential, one pin or one group of bearing surfaces at a time. Once the crankshaft is supported vertically between the centers in the first work station 33, the induction coil assembly 48 moves to its position and as the crankshaft rotates, the coil assembly 48 generally follows the spindle orbit selected at the same speed and inductively heats the spike. This heating step, approximately 10-20 seconds. Once the crankshaft shank is heated to the desired temperature, the cooling step needs to be performed. This is achieved in one embodiment by a sudden increase in cooling water through the coil assembly and directly on the spigot that has been heated (Figure 6A). In another embodiment of the present invention, the coil assembly is decoupled and the crankshaft continues to rotate while operating a separate cooling station. The crankshaft continues to rotate while the cooling step is performed regardless of the mode. Once the induction hardening of this first pin is finished, the crankshaft graduates vertically in both. that the coil assembly remains fixed in order to place the next crankshaft pin. This procedure is repeated until all the crankshaft pins have been heated inductively and hardened with cooling. The drive systems for the coil assembly are programmed to recognize which spike is selected and the X and Y drive systems that were tested to plot a preselected orbit for that particular spike. Since several modalities have been described, one must determine if any counterweight adjustment is desired and if so, what type of adjustment will be made. The trip in X and Y of the coil assembly is still the same for each spike, once the starting position is determined. Each pin has a different circumferential location relative to the rotational pressure of the crankshaft and thus the starting position of the coil assembly varies depending on the selected pin. The induction coil assembly 48 in the first work station 33 is initially positioned relative to the selected spigot before the rotation of the crankshaft. Therefore, the X-Y tracking route for the orbital coil assembly of the spigot needs to have a tracking speed that is synchronized with the speed of the crankshaft. The speed and route of the coil assembly are critical and must correspond precisely to the speed of the crankshaft and the orbit of the spigot. Even though the spacing between the coil assembly and the spike varies, there is still a specific tracking orbit that is plotted in each cycle. This is not a matter for the bearing surfaces due to the coaxial nature and its orbit.

As explained, the induction hardening of the crankshaft pins can be terminated prior to induction hardening of the bearing surfaces or after induction hardening on all bearing surfaces. The spikes and bearing surfaces can be processed in two different work stations as part of an apparatus or by two separate apparatuses, one dedicated to the spikes and the other dedicated to the bearing surfaces. As illustrated in Figures 5 and 6, a typical coil assembly includes a copper heating element (inductor) 93, an internal cooling jacket 94, a field focusing portion 95 of the plastic material suspended in iron, a spacer 96, and a setter block 97. The field focusing portion is used to manipulate the magnetic flux field. The cooling capacity is installed in the coil assembly, the inner surface 57 is provided with a plurality of holes in a compact and uniform pattern as illustrated in Figure 6A. When the cooling function is performed by a separate cooling mechanism, the cooling mechanism is located between the ends of the crankshaft in a positioning mechanism (not shown) as is well known in the art. The logic programming circuit of the present invention discussed below is intended to apply induction hardening to the crankshaft pins and not to the bearing surfaces. This is due to the type of rotational orbit that the pin has relative to the longitudinal axis of the crankshaft in contrast to the concentric or coaxial location of the bearing surface for the axis area of the crankshaft. The first point of the data that is to be provided is the coupling position for both the X and Y drive systems so that the corresponding induction coil assembly is properly positioned relative to the corresponding spigot that is going to heat inductively and harden with cooling. The additional data that will be programmed in the logic circuit computer control is derived from the particular specifications of the crankshaft. These data include the size, shape, and geometry of the crankshaft, including the spikes and any counterweights. The data referred to is entered on average on a keyboard (manual entry). Once the part specification data, phasic, is entered, this will not change and will be the same regardless of whether the crankshaft shank is heating effectively and hardening with cooling. It is to be noted that the coupling position may or may not change, depending on how well the particular crankshaft has been manufactured in relation to its design and tolerance dimensions. The data by additional information that the operator can enter into the programming logic circuit for the present invention by means of the keyboard includes the tolerances by spike, number of revolutions, the rotation time, the heating time, the rotation speed and the Power supply output. The rotational speed in RPM during heating is usually adjusted so that there are two RPMs, one per hemisphere. In one hemisphere, the shaft that rotates at 30 RPM and in the other, is rotated at 50 RPM. This can be subdivided into quarters or even into smaller sections. It should be understood that the rotational speed can be decomposed into smaller cooling, allowing gradual acceleration and / or gradual deceleration as described herein. It is also to be noted that the present invention can be pre-programmed to follow any circular path or electrical path, depending on how the heat of the induction coil assembly needs to be concentrated. In these various route portions are discussed herein with respect to the alternative embodiments of the present invention. As will be understood, when a circular orbit is followed by the induction coil assembly, the drive system of the X axis follows a cosine waveform of the drive system of the Y axis follows a sine wave. With respect to the use of the apparatus 20 consistent with the present invention, the process is started by the robot and / or operator placing the crankshaft in the lower center support and then holding it or placing it in a clamping press on the upper part in order to to start the cycle. In the directions X and Y are horizontal and as described, these two drive systems are connected to each other at 90 °. The rotational movement referred to as theta (r) defines the rotation of the drive / crankshaft spindle. The axis of the Z is in the vertical direction and represents the positioning axis for the coil and induction assemblies and the crankshaft in a vertical direction.

The first step involves movement in the direction of the Z axis by the crankshaft moving in a position where the spike that is selected for induction heating is placed in a "known" location that is referred to as zero degrees theta ( r). Once the crankshaft shank moves to the desired vertical location, the crankshaft is rotated until the theta reading (r) is 0 degrees based on the input of a photosensor switch. Once the position of theta (r) of 0 degrees is determined, the system moves the crankshaft along the axis of the Z (vertical) downward in the position of the coil, which is the position that will inductively heat that particular spike. Once the Z-axis and the theta (r) locations are improperly adjusted, then the drive system of the X-axis engages to move the induction coil assembly to its coupling point that will be aligned with the corresponding spindle of the crankshaft. Then, the drive system of the Y axis is engaged to move the induction coil assembly on the crankshaft. As shown in the corresponding drawings, when it is arriving directly at the point of the machine (see Figure 3), the direction of the axis of the X is to the left and right and the direction of the axis of the Y is to and from of the machine. Therefore, once the positions of X and Y are set and the crankshaft is set to zero degrees theta (r), the system starts to rotate (in the direction of theta (r)), going in a direction in the direction counterclockwise. After the turning movement in the direction of theta (r) begins, the drive system of X and Y follows the particular orbit of that spike, making a corresponding path in the counterclockwise direction. While an address has been selected in the counterclockwise direction, it is. it should be noted that the theta (r) address can be either clockwise or counterclockwise. It will also be pointed out that in a decoupling position which is the theta position (r) in degrees, it is also possible to decouple the X and Y drive systems safely, by extracting the induction coil assembly from its relation to the crankshaft without "conditioning" the machine. As the crankshaft is turned in a theta direction (r), in the counterclockwise direction, it goes from a 0 degree location reading all the way around to a 360 degree location. At the present time, the decoupling position is programmed to approximately 240 degrees. What actually happens is that the induction coil assembly rotates out of engagement such as the gears that rotate out of the intermeshing relationship. The particular decoupling position is based on the specifications of the part and thus, as the parts change, the decoupling point can also be changed. However, the decoupling positions will generally be in the third quadrant of the circular path of the corresponding crankshaft pin. Once the induction heating cycle is completed, the controller, which in the case of the present invention is an Alien Bradley Slick 500, will actually indicate that the heating phase has been completed. At this point, the drive units X and Y control the decoupling of the induction heating coil, which at the present time is 240 ° theta (r). When uncoupling, the direction on the Y axis of the movement is initially activated to return the coil from its heating position. The X axis will be really coupled in order to follow the part so that it does not hit the sides of the coil. Once the Y trip is approximately 3 inches off the programmed axis, it is possible to uncouple the drive system from the X axis and thus stop X from moving. In this point, the drive system in X and Y return to the starting position or load position for the next spike. It is to be noted that the spigot assembly disengages from the crankshaft while the crankshaft continues to rotate. This particular decoupling protocol allows the crankshaft to rotate during the cooling cycle as long as the spiral is decoupled. This particular protocol allows shorter cycle time of uniform cooling. Indeed, since it is possible to do this, it is to uncouple the spiral and lower the crankshaft in the direction of the axis of the Z and continue with complementary cooling at that point while the next crankshaft pin is placed for induction hardening. This allows the next spike to be placed in the ready position while the cooling site for the previous spike is continued. As indicated, this allows for shorter cycle times while not adversely affecting uniform cooling. A variety of equipment designs and configurations have been illustrated and described with reference to Figures 1-17. In each case, the representation selected for the induction coil assembly is that it can best be described as a 90 degree coil, due to the fact that there are two routes or 90 degree fields, connected. In the construction of this coil style for the induction coil assembly, a flow of current through the actual coil comes and goes through the centrally connected connecting support arm. There is a current path of 90 degrees of exit and return on one side of the support arms and a current path of 90 degrees, heated on the opposite side of the support arm. With reference to Figures 18, 18A and 19, n 90 ° coil assembly 300 is illustrated. The coil assembly 300 includes the coil 300a and the support arm 300b. The support arm 300b is constructed with an input current portion 301 and an output current portion 301a. These two portions are electrically isolated from each other and are actually staggered from the upper part to the bottom relative to each other with respect to the ends connecting the coil 300a. The portions 302 of an insulating, electrical material are laminated around and between the portions 303 of the copper conductive material. The incoming current from the connected transformer travels to the coil 300a via the portion 301. The current then travels approximately 90 ° around the exposed surface 304 of the coil 300a from point A to the upper portion of the portion 303a. The return path is from the bottom 303a back to point B. The return path is also approximately 90 °. This 90 ° route is the basis for describing the coil assembly 300 as a 90 ° coil. As used herein, expressions such as the following "90o coil", "90o induction coil" and "90o coil construction" each refer to an induction coil having an overall semi opening -Indicator and a supporting arm that carries the current to and from the coil.The support arm is positioned relative to the symmetrical opening such that it is effectively centered and in this way there is a portion of approximately 90 ° of the opening of coil extending far from one side of the support arm of a first direction and another portion of approximately 90 ° of the coil opening extending from the other (opposite) side of the arm is supported in the second direction. it is clearly illustrated in Figure 18 and the reference of "90 degrees" refers to the running travel of the support arm to an end or edge of the semi-cylindrical aperture, portions 303b and 303c are isolated by portion 302a of l electrical insulation material. The portion 303d including the point B is centered on the center line of the support arm 300b and on the center line of the coil 300a. The centerline of the support arm 300b is also coincident with the center line of the insulating strip 303 which is positioned between the portion 303 and the portion 301a. The current flow through the portion 303d is from the lower point B to the upper point C. The point C, start the next 90 ° current route (second). This flow path is from point C through portion 303e through portion 303f, along exposed surface 304. This point, the current path travels down through portion 303f to the portion 303g. The outlet of portion 303g is back to outlet portion 301a of support arm 300b. The construction of the coil assembly 300, as illustrated in Figures 18, 18A, and 19, is capable of including a cooling capacity with water and providing cooling openings according to what is illustrated in Figure 6A on the surface 304 of coil 300a. The communication with these cooling openings are cooperating passages that are formed inside the coil 300a. Many cooling openings are not illustrated in Figure 19 simply by clarity of the drawing so as to be able to clearly illustrate the corresponding conductive and non-conductive portions and current paths. The style of assembly 300, as illustrated in Figures 18, 18A, and 19, is suitable for use in the embodiments illustrated in Figures 1-17 and for induction hardening of workpieces that are processed by those embodiments illustrated. However, it has been learned that an alternative coil assembly study (180 °) is preferred for the induction hardening of the selected portions of the parts of certain workpieces, such as the crankshafts. The alternative style (ie "centering") of the coil assembly 310 is illustrated in Figures 20, 21, and 22. The 180 ° description and the "centering" style reference for the coil assembly 310 comes from the made that the collection support arm 311 is positioned along one side of the current coil 310a such that the current flow travels in a route of approximately 180 ° through the upper surface 312 of the coil 310a before traveling downward from the front surface 313 and back 180 ° through the surface of the bottom side 314 back to the support arm 311. The current flow path for the coil assembly 310 is illustrated by the arrows 315. It will be understood that , since between the 90 ° coil style and the 180 ° coil style, the 90 ° coil mounting style is closer to the state of the art by industry standard. Accordingly, it should be understood that the 180 ° centering style of the coil assembly 310 as described herein is a unique and new design and deviates from the industry standard. The "centering" reference when describing coil 310a comes from the location of the support arm that is centered in the center. The construction details of the coil assembly 310, including the coil 310a and the support arm 300, are illustrated in Figures 20, 21 and 22 which are described hereinafter. Some of the basic construction details of coil assembly 310 follow the well-known design principles for induction hardening coils. The focus of the uniqueness and novelty of the coil assembly 310 is in the specific configuration of the coil 310a and importantly in the corresponding current flow path including the 180 ° travel around the coil as described. As used herein, the expression is such, "off-center 180 ° coil," "180 ° induction coil," "centering", and "coil 180 ° centering style" each refers to a induction coil having a generally semi-cylindrical opening and a supporting arm that conducts the current to and from the coil.The support arm is connected to the coil along one side of the coil such that approximately 180 ° of the semi-cylinder opening of the coil extends from the upper arm. the current that is distributed to and from the coil by means of the support arm travels from the support arm to the opposite end of the coil, approximately 180 °, and then returns to the support arm. This style of induction coil is described as being "off center" because the support arm is not centered relative to the coil but is actually centered on one side of the complete coil. This construction is clearly illustrated in Figure 20. With continuous reference to Figures 20, 21, and 22, the support arm 311 is configured with two conductive portions 318 and 319 (one positive, one negative) that separate and electrically insulate each other. (and insulated) by the insulating panel 320. The connection block 321 is designed to be mechanically and electrically connected to an electrical common bar (not shown) that is operably connected to a transformer (not shown). The block 321 connects mechanically and electrically to each of the two conductive portions 318 and 319. The heating current flows from the transformer through the conductive portion 318 back to the transformer via the other conductive portion 319. Placed in block 321 are two water passages 324 and 325 and each conductive portion includes a corresponding and connecting passage 326 and 327. Passage 326 in portion 318 is in communication for flow with passage 324. Passage 327 in the portion 319 is in communication for flow with passage 325. Threaded fasteners 328 are used to help connect the two conductive portions 318 and 319 together and mechanically sandwich and secure the insulating panel 320 between the two conductive portions. The end 329 of the support arm 311 (i.e., the mounting of the two conductive portions 318, 319 in combination with the insulating panel 320) is connected to one side 330 of the coil 310a by 180 °. The insulator 331 limits the electrical connection of the support arm 311 to the reel 310a to the located area of the end 329. The block 332 is used as a reinforcement to secure and strengthen the connection of the support arm 311 to the reel 310a. The threaded fasteners 333 are used to join the block 332 to the rear surface 336 of the coil 310a and the longitudinal side 337 of the portion 319. The incoming flow of current travels through the transverse portion 318, turns the corner in the end 329 and flows approximately 180 ° through the upper surface 312 of the coil 310a. The current flow path then follows the front surface 313 and flows to the bottom side surface 314. At this point, the current flows 180 ° back around the coil 310a to the portion 319, and from there along from the underside of the portion 319 back to block 321. The heating dynamics of this current flow path for 180 ° off-center coil assembly 310 distributes power to the upper edge and then to the bottom edge and to the latter the portion central. The current path through the upper surface 312 is in the form of a half-circle of at least 180 °. The curvature of the route coincides with the curved and cylindrical geometry of the inner surface 310b of the coil 310a. The inner surface 310b extends by at least 180 ° and represents the surface that is adjacent to the portion of the workpiece to be hardened by induction. What has been learned from a comparison of heating patterns and heat treatment results between a 180 ° coil assembly and the 90 ° coil assembly is that the 90 ° coil assembly creates a heating dynamic that starts in the central area of the workpiece, and in particular the selected portion of the workpiece, such as a stem of a crankshaft before it reaches the adjacent or outer corners. In certain situations where heat treatment is desired in the corner portions, the central portion will get too much heat before the heat gradually reaches equines. The cause and effect of this situation is due to the current path of 90 and the fact that only a quarter of the spike is heated at the same time (position) and the amount of heat is less for the fixed mass. In contrast, coil 310a of 180 ° has a current path that starts by heating the corner portions first and then reaches the central portion. It is worth noting that the design of the inner spigots and pipes of a crankshaft, the inner corners that are discussed herein are locations in greater mass as compared to the actual spigot or pipe. By heating the higher mass applications first, the heat builds up without overheating the smaller portions. Figures 23, 24 and 25, schematically illustrate the results of the heating pattern (heat treatment) for different component portions for the coil assembly 300 of 90 ° and for the coil assembly of 180 °, 310. The heating patterns of Figure 23 are for a main pipe bearing 338 and the outer edges or corners 339, 340 do not represent various criticisms from the perspective of higher hardness and strength requirements. Accordingly, any coil assembly style 300 or 310 can be used for an outer pipe bearing. When the main, inner bearings are being hardened, the heat treatment pattern needs to include the inner corners because the corner strength is critical due to the torsional loads. With the 90 ° coil assembly 300, the heating pattern for a main, inner or main bearing as shown in Figure 25. As illustrated, the inner corners 342, 343 do not receive sufficient heat treatment in order to achieve the hardness and resistance desired or necessary. In contrast, the heating pattern of Figure 24 is achieved by the use of coil assembly 310 to 180. Here the inner coils 344, 345 on each side of the cylindrical (or spigot) main bearing 346 are sufficiently treated with heat to acquire the desired hardness and strength. As will be understood, the 90 ° coil assembly 300 is suitable for use by the exterior pipes (number 1 and number 5), while the 180 ° coil assembly 310 should be used for interior pipes (numbers 2, 3 and 4) as an example. While the hardening patterns created by the use of 180 ° coil assembly are extremely important, there are other benefits derived from the use of the 180 ° coil assembly compared to the 90 ° coil assembly. Using a crankshaft as an example, tests have shown that for a typical adjustment using the 90 ° coil assembly 300, it takes approximately 18 seconds to properly heat the spike for the desired heat treatment condition. With the 180 ° coil assembly 310 under virtually identical conditions, otherwise, it takes approximately 11 seconds to properly heat the spike for the desired heat treatment condition. Even the time savings are directly related to the fact that when heating the locations of higher mass first than those of minor, no time is wasted or it is wasted being these locations obtain the necessary temperature. Additionally, with a 310 ° coil of 180 ° there is a larger mass area for water cooling through the coil which allows even a higher thermal capacity and a higher power capacity. The thermal capacity of the 180 ° coil doubles effectively compared to the 90 ° coil. The 180 ° coil is preferred over the 90 ° coil when less complexity is desired or when a greater or stronger electric field is desired. The 90 ° coil generates less power, uses less copper, and allows less fluid flow for cooling. The heat treatment patterns illustrated in Figures 23-25 are derived from the micro-operation of real parts that have been induction hardened using both 90 and 180 ° coil assemblies. It is the unique and important heat treatment pattern of Figure 24 which has been discovered to be achievable by the use of the new and non-obvious 180 ° off-center coil assembly 310 which has been illustrated and described herein.

The arrangement of the main bearings, pins and counterweights varies to some degree with the style of the machine. For example, a six in lines has three pairs of spikes that can be heat treated (ie, harden by induction), in pairs due to their identical location relative to the dead center position of the top. As it is generated, the spikes 3 and 4 can be processed together, concurrently, since as can the spikes 2 and 5 as well as the spikes 1 and 6. In a V-6 machine the six spikes are grouped in 3 pairs in order to properly balance the V-6 machine. The two pins of each pair are adjacent to each other are described as "slit pins", this can be considered as a unique situation from the perspective of induction hardening, but the crankshaft for a V-6 machine is still a relatively configuration common. A pair of "slit pins" of the crankshaft pins 351 and 351 are illustrated schematically in Figure 26. These pins are rotatably swiveled by a 30 ° offset by the proper roll of the V-6 machine. The region 352 is placed between the two pins 350 and 351 has an inherent weakness because it is the thinnest section or portion of the crankshaft. Figure 27 is a schematic illustration of what region 352 looks like in the side section due to the cylindrical nature of pins 350 and 351 and the fact that these two cylindrical pins are changed relative to each other, so that its cylindrical axes are not coincident. The shape of sector 352a of region 352 through section 27-27 is referred to as a "soccer" or soccer form due to its geometry. Included as part of the partial crankshaft illustrated in Figure 26 are the counterweights 353 and 354. The heating sequence (i.e., induction hardening) starts with the inner radiated corners 355a and 355b. This is followed by heating (i.e., induction hardening) of the joints (ie spikes 350 and 351). Consistent with what has been described with the inner corners 344-345 of Figure 24, the inner corners 355a and 355b are regions of greater mass. The 180 ° coil design generates more unit heat, partly because it is heated first. The resulting heating pattern is also illustrated in Figure 26. Another option to control the amount of heat input into the crankshaft or other work piece is to vary the rotation speed of the crankshaft depending on the mass that is present adjacent to the coil . When the induction hardening coil is adjacent to the narrowest portion of the counterweight, for example, the rotation diversity is faster because less heat input is required. As the crankshaft rotates and the largest portion of counterweight is placed adjacent to the coil, the rotation speed is less so that more heat can be introduced. In accordance with the present invention, the preferred approach for induction hardening of pins 350 and 351 is to use, concurrently, 180 ° off-center coil assemblies 310 (see Figure 28). Since there is an offset at 30 ° or change, the two coil assemblies will have a similar change or offset in the direction at or normal to the plane of the paper. By lining the two coil assemblies in the two pins 350 and 351 of the crankshaft, the transition region 352 is not heated directly. On the other hand, the heating of the pins will bring sufficient heat to the region 352, considering the thinnest mass of this. region, to effect the induction hardening, desired. Since there are three pins of the pins offset, the heating (induction hardening) described for the pins 350 and 351 is basically the same for the other two pairs of pins. As shown in Figure 28, each 180 ° off-center coil assembly 310 is electrically and mechanically connected to a corresponding transformer 357 and 358. Each transformer is mounted on its own table 359 and 360 X placement., And corresponding. The proximity of the pins 350 and 351 presents a challenge of induction hardening due to the heating of a pin without the concurrent heating of the adjacent pin this makes a tempered backing of the edges of the adjacent pin. The proximity of the two pins is close enough that the heat generated by induction hardening has a spike capable of being isolated from the adjacent spike in order to prevent tempered backing. If the pins 350 and 351 do not harden by induction at the same time, the intermediate region 352, the position of connection between the two pins, remains a soft zone with insufficient hardness. The arrangement of Figure 28 of the two coil assemblies 310, off-center is illustrated for induction hardening of slit pins 350 and 351 as part of the V-6 machine crankshaft. The illustration of Figure 29 depicts the use of two coil assemblies, off-center 310 for induction hardening of a 6-line crankshaft. The only "difference" between the arrangements illustrated in Figures 28 and 29 is in style or type. of crankshaft that hardens by induction. With reference to Figure 30, another feature of the present invention is illustrated. The 90 ° coil assembly 300 is suitable for the exterior pipes of a crankshaft 356 of coil assembly 310 of 180 ° refers to the inner pipes of the crankshaft. The use of two different styles of induction coil assemblies in the same work piece, requires that when in use, both styles of coil assembly have the same axial center line, so that the crankshaft never has to be changed or moved. The axis of each induction coil 300a, 310a, of each coil assembly 300, 310 known with the vertical or longitudinal axis of rotation on the crankshaft 356, once the pipes move in position for contactless orbital tracking as shown in FIG. describes in the present. It is preferred to decentralize or divert the two transformers 357, 358 instead of having to change the vertical axis the crankshaft 352 of the alignment with a coil assembly 300 to align with the other coil assembly 310. In accordance with the present invention, it is it is possible to connect a 90 ° coil assembly 300 to the first transformer 357 and a 180 ° coil assembly 310 to the second transformer 358. As long as this 90 ° coil mix with a 180 ° coil is possible, the It is likely that the same style of coil will be used throughout, as illustrated in Figure 28 (V-6) and Figure 29 (in-line-6). The two transformers are decentralized or change with each other, but the coils can be placed so that for 6 cylinders in line, the axial center lines of the coils coincide with each other and with the vertical axis of rotation of the crankshaft 356, when the coils are move in your position. Each transformer moves in its own laying table 359, 360 of X, Y, corresponding as briefly described for the positioning of the induction glide coils according to the present invention. It should be noted that the center, axial lines of the coils do not coincide with each other and with the vertical axis of rotation and the crankshaft for the configurations in V-6 (see Figure 28). While the invention has been illustrated and described in detail in the drawings and the foregoing description, it is to be considered as illustrative and not restrictive in character, it is understood that only the preferred embodiment has been shown and described and that they are desired. protect all changes and modifications that come within the spirit of the invention.

Claims (26)

1. An induction hardening apparatus for inductively heating and cooling hardening a workpiece, the induction hardening apparatus is characterized in that it comprises: a fastening means for positioning and supporting the workpiece at a workpiece location; a rotary drive means for rotating the workpiece; an induction hardening station positioned adjacent to the workpiece location and including a contact-free induction coil of a contact-free positioning system for moving the induction coil in a predetermined path; a control means for generating data of the path of the coil based on the geometry and dimensions of a portion of the workpiece to be hardened by induction, the control means that is operatively connected to the positioning system; and the portion of the work piece that moves in an orbital route during the rotation of the work piece and the predetermined route generated by the positioning system serving the orbital route, whereby the spacing between the inner surface of the induction coil and the portion of the workpiece during the rotation of the workpiece that remains substantially uniform, the induction coil moving to be free from any contact with the portion of the workpiece.

2. The induction hardening apparatus according to claim 1, characterized in that the induction coil is a 180 ° coil, misaligned.

3. The induction hardening apparatus according to claim 2, characterized in that the positioning system includes X and Y drive systems arranged one with respect to the other at a right angle.

4. The induction hardening apparatus according to claim 3, characterized in that the fixing means includes a pair of central supports, oppositely placed to place and support the crankshaft.

5. The induction hardening apparatus according to claim 4, characterized in that the orbital route is circular.

6. The induction hardening apparatus according to claim 5, characterized in that the positioning system further includes electronic control in the X and Y drive systems.

7. The induction hardening apparatus according to claim 6, characterized in that it includes a second induction coil with a coil construction of 90 °.

8. The induction hardening apparatus according to claim 1, characterized in that the 180 ° coil is operably connected to a first transformer and the 90 ° coil is operably connected to a second transformer.

9. The induction hardening apparatus according to claim 8, characterized in that the workpiece is a crankshaft.

10. An induction hardening apparatus for inductively heating and hardening a crankshaft by cooling, the induction hardening apparatus is characterized in that it comprises: a fixing means for positioning and supporting a crankshaft at a crankshaft location; a rotary drive means for rotating the crankshaft; an induction hardening station positioned adjacent to the crankshaft location and including an induction coil and positioning system for moving the induction coil in the predetermined path; a control means for generating data of the path of the coil based on the geometry and dimensions of a portion of the crankshaft to be hardened by induction; and the portion of the crankshaft that moves in an orbital route during the rotation of the crankshaft and the predetermined route generated by the positioning system that follows the orbital route, whereby the spacing between the interior surface and the induction coil and the portion of the crankshaft during the rotation of the crankshaft which remains substantially uni form.

11. The induction hardening apparatus according to claim 10, characterized in that the induction coil is a coil of 180 ° misaligned.

12. The induction hardening apparatus according to claim 11, characterized in that the positioning system includes X and Y drive systems arranged one with respect to the other at a right angle.

13. The induction hardening apparatus according to claim 12, characterized in that the orbital route is circular.

14. The induction hardening apparatus according to claim 13, characterized in that the positioning system also includes. an electronic control of the X and Y drive systems.

15. The induction hardening apparatus according to claim 14, characterized in that the induction coil is constructed and arranged with cooling fluid openings to distribute a cooling fluid to the crankshaft portion.

16. The induction hardening apparatus according to claim 15, characterized in that it includes a second induction coil with a coil construction of 90 °.

17. An induction hardening coil assembly for the induction hardening of a portion of a workpiece, the induction hardening coil assembly having a misaligned 180 ° construction, and is characterized in that it comprises: a coil body that defines a generally semi-cylindrical opening extending aximately 180 ° about an axis of the coil; and a support arm attached off the shaft along one side of the coil body such that the semi-cylindrical opening is completely placed on one side of the support arm as the support base providing an electrical connection between the coil body and a source of electric current.

18. An induction hardening apparatus for inductively heating and cooling hardening a workpiece, the induction hardening apparatus is characterized in that it comprises: a fastening means for positioning and supporting the workpiece at a workpiece location; a rotary drive means for rotating the workpiece; an induction hardening station positioned adjacent the workpiece location and including an induction coil and positioning system for moving the induction coil in a predetermined path, the predetermined path based on the geometry and dimensions of the induction coil a portion of the workpiece to be hardened by induction; and the portion of the work piece that moves in an orbital route during the rotation of the work piece and the predetermined route generated by the positioning system that follows the orbital route, whereby there is a space between the interior surface of the workpiece. the induction coil and the portion of the workpiece during rotation of the workpiece, the spacing remaining substantially uniform, the induction coil moving to be free of any contact with the workpiece portion.

19. An induction hardening apparatus for inductively heating and cooling hardening a workpiece, the induction hardening apparatus is characterized in that it comprises: a fastening means for positioning and supporting the workpiece at a workpiece location; a drive means for moving the work piece in the desired path; an induction hardening station positioned adjacent to the location of the workpiece and including an induction coil and positioning system for moving the induction coil in a predetermined path; a control means for generating data from the path of the coil based on the geometries and dimensions of a portion of the workpiece to be hardened by induction, the control means that is operatively connected to the positioning system; and the portion of the work piece that moves in an orbital path during the rotation of the work piece and the predetermined path generated by the positioning system that follows the orbital path so that there is a space between the inner surface of the induction coil and the work piece portion during the rotation of the workpiece, the spacing having a variable dimension during at least one revolution of the workpiece, the induction coil moving to be free from any contact with the piece of work.

20. In combination: a crankshaft including a plurality of substantially cylindrical pins and a plurality of substantially cylindrical bearing surfaces that are in alternating sequence with the substantially cylindrical pins; and an induction hardening apparatus for inductively heating and hardening the crankshaft by cooling, the induction hardening apparatus is characterized in that it comprises: a first work station for inductively hardening the plurality of substantially cylindrical pins; a second work station for inductively hardening the plurality of substantially cylindrical bearing surfaces; a robotic device constructed and arranged to move the crankshaft from the first workstation to the second work station; and the first work station including a fixing means for positioning and supporting a crankshaft at a crankshaft location, a rotary drive means for rotating the crankshaft, an inductive, movable coil that is constructed and arranged to inductively harden a spike at a time and a positioning system for moving the induction coil in a predetermined path that follows the path of the spike as the crankshaft rotates, the positioning system maintaining a substantially uniform distance of separation between the inner surface of the induction coil and an outer surface of the pin during the rotation of the crankshaft.

21. A method for inductively hardening a crankshaft with a plurality of pins and a plurality of bearing surfaces by the use of an apparatus including a fastening means for positioning and supporting a crankshaft at a crankshaft location, a rotary drive means for rotating the crankshaft, an induction coil, a positioning system for moving the induction coil in a predetermined route, and a control means, the method which is characterized in that it comprises the steps of: a) loading a crankshaft into a medium of fixation to support the crankshaft vertically between centers; b) selecting one of the plurality of crankshaft pins for induction hardening; c) entering the geometry and dimension data for the selected spike in the control means; d) activate the positioning system to place the induction coil adjacent to the selected spigot; e) energizing the positioning system concurrently with the rotary drive means such that according to the spike, its rotating orbit is swept, the induction coil follows that orbit; f) electrically energizing the induction coil in order to inductively heat the selected spigot; and g) cooling the selected spike.

22. An induction hardening apparatus for inductively heating and hardening a crankshaft by cooling, the induction hardening apparatus is characterized in that it comprises: a fixing means for positioning and supporting a crankshaft at a crankshaft location; a rotary drive means for rotating the crankshaft; an induction hardening station positioned adjacent to the location of the crankshaft and including a contact-free induction coil and a contact-free positioning system for moving the induction coil in a predetermined path; a control means for generating data on the path of the coil based on the geometry and dimensions of a portion of the crankshaft to be hardened by induction, the control means that is operatively connected to the positioning system; and the portion of the crankshaft that moves in an orbital route during the rotation of the crankshaft and the predetermined route generated by the positioning system that follows the orbital route, whereby the dimension of spacing between an interior surface of the induction coil and the crankshaft portion during rotation of the crankshaft changes during at least one revolution of the crankshaft, the induction coil moving to be free from any contact with the crankshaft portion.

23. An induction hardening apparatus for inductively heating and hardening a crankshaft with cooling, the induction coating apparatus is characterized in that it comprises: a fixing means for positioning and supporting a crankshaft at a crankshaft location; a driving means for moving the crankshaft in a desired route; an induction hardening station positioned adjacent to the crankshaft location and including an induction coil and positioning system for moving the induction coil in a predetermined route, the predetermined route that is based on the geometry and dimensions of a portion of crankshaft to be hardened by induction; a cooling medium for the distribution of a cooling fluid; and the crankshaft portion that moves in an orbital route during the rotation of the crankshaft and the predetermined route generated by the positioning system that follows the orbital route, whereby the dimension of spacing between an inner surface of the induction coil and the crankshaft portion during the rotation of the crankshaft changes during at least one revolution of the crankshaft.

24. In combination: a crankshaft including a plurality of substantially cylindrical pins and a plurality of substantially cylindrical bearing surfaces that are in an alternating sequence with the substantially cylindrical pins; and an induction hardening apparatus for inductively heating and hardening the crankshaft with cooling, the induction hardening apparatus is characterized in that it comprises: a first work station for induction hardening of the plurality of substantially cylindrical pins; a second station. of work for induction hardening of the plurality of bearing surfaces, substantially cylindrical; a robotic device constructed and arranged to move the crankshaft from the first workstation to the second work station; and a first work station including a fixing means for positioning and supporting a crankshaft at a crankshaft location, the rotary driving means for rotating the crankshaft, and a plurality of inductive, mobile coils, each coil induction of the plurality that is constructed and arranged to inductively harden a corresponding spike, and a positioning system for moving the induction coil in a predetermined route that follows the corresponding spindle path as the crankshaft is rotated, the positioning that maintains a substantially uniform distance of separation between an inner surface of each induction coil and an outer surface of the corresponding spigot, during rotation of the crankshaft.

25. In combination: a crankshaft including a plurality of substantially cylindrical pins and a plurality of substantially cylindrical bearing surfaces that are in an alternating sequence with the substantially cylindrical pins; and an induction hardening apparatus for inductively heating and hardening the crankshaft with cooling, the induction hardening apparatus is characterized in that it comprises: a first work station for injection hardening the plurality of substantially cylindrical pins; a second work station for inductively hardening the plurality of substantially cylindrical bearing surfaces; a robotic device constructed and arranged to move the crankshaft from the first workstation to the second work station; and the first work station that includes a fixing means for positioning and supporting a crankshaft at a crankshaft location, a driving means for moving the crankshaft on a desired path, an inductive, mobile coil that is constructed and arranged for Inductively hardening one pin at a time and positioning system to move the induction coil in a predetermined path that follows the path of the pin as the crankshaft rotates, the positioning system maintaining a substantially uniform distance of separation between an inner surface of the induction coil and an outer surface of the pin during the rotation of the crankshaft.

26. A positioning system for moving an induction coil in a predetermined path following the path of a spindle of a crankshaft as the crankshaft is rotated to place the induction coil in a position of induction heating relative to the spike, the system of positioning which is characterized in that it comprises: a drive system of the X axis connected to the induction coil by means of a transformer and a common bar; a driving system of the axis of the Y connected to the drive system of the axis of the X whereby two degrees of movement are provided for the induction coil; and an extraction means for moving the induction coil out of the induction heating position while the crankshaft continues to rotate. SUMMARY OF THE INVENTION An induction hardening apparatus (20) for inductively heating and cooling hardening a crankshaft (21) includes an array of two work stations (33,36) similarly configured and a robotic device (37) that grades the crankshaft from a first work station to a second work station. The induction hardening apparatus is designed with an induction coil (48) located in the first work station for induction, sequential heating and hardening with cooling of the crankshaft pins. In the second work station, an individual induction coil (63) is used for the bearing surfaces of the crankshaft. A feature of the present invention is that the induction coils do not contact the surface of the crankshaft which are inductively heating and hardening with cooling. The dimensions and geometries of the crankshaft are programmed in servo drive systems (49, 51) that move the corresponding coil in the X and Y directions that follow exactly the orbit or path of each pin and each bearing surface. Another feature of the present invention is the use of a 180 °, off-center or misaligned coil (310) that provide improved heating patterns in less time than traditional 90 ° coils.