Schaeffler provides its customer TAKRAF GmbH with a solution for the induction heating of components weighing up to five tons in the shortest possible time. The FAG HEATER5000 is a special heating device capable of supplying the electric power required for such massive workpieces. It is equipped with the Delta T control system, a new technology that makes safe and homogeneous heating possible by monitoring the temperature difference between the inside and outside of the component. Compared to conventional heating devices, customers using the FAG HEATER5000 can achieve time savings of up to 95% and thus significantly improve the process as well as optimizing cost and personnel outlay.
Mounting XXL gears – a challenge
TAKRAF manufactures roll crushers together with the corresponding gear boxes, which represent a new product sector. These gearboxes comprise large and heavy components such as gears that weigh up to five tons. TAKRAF already uses inductive heating devices from FAG that are suitable for masses of up to 1,200 kilograms for heating their smaller workpieces. Since these devices are not able to heat the large gearbox components, the customer needed a new device with considerably more power. The local Schaeffler sales engineer forwarded this request to the specialists responsible at the Global Technology Network.
Customer-specific solution with the FAG HEATER5000
Schaeffler developed a special heating device that is capable of delivering the electric power that is needed for workpieces weighing up to five tons. In order to also ensure safe and homogeneous heating, this additionally employs a new technology – the Delta T control system. Two magnetic sensors monitor the temperature level on the inside and outside of the workpiece and limit the power as soon as the maximum permissible difference is exceeded. This minimizes the danger of changes to the material structure. The heating process on the FAG HEATER5000 is controlled using a touchscreen and, in addition to the Delta T function, it can also be controlled according to time or temperature. Three different ledges allow workpieces with different inside diameters to be heated. The FAG HEATER5000 was put into operation at the customer’s premises by a Schaeffler expert, who then determined its functionality and specific features. This special heating device allowed TAKRAF to significantly improve its mounting process. Even with gears weighing just 2,000 kilograms, which were previously heated using the FAG HEATER1200, it was possible to reduce the time from six hours to 20 minutes.
The induction heating devices in the FAG HEATER series fulfill the highest standards of quality and safety. The different sizes available in the standard range already fulfill a wide range of requirements. From the smallest device (the FAG HEATER10) to the largest (the FAG HEATER1200), they allow rolling bearings and other workpieces from ten to 1,200 kilograms to be heated quickly and effectively. Schaeffler delivers the matching accessories, such as various ledges, the corresponding special grease, heat-resistant gloves, and a cover as standard with all devices. Schaeffler offers a free device selection program – FAG Heating Manager – to help users select the optimum heating device for their rolling bearings; this software is available to download from the Media Library at www.schaeffler.de.
