February 2021 Volume 3

AUTOMATION

Figure 6. iHaz numerical simulation software To further automate the InductoForge control process, the system utilizes iHAZ, a numerical simulation software package. The software enables the user to create process recipes for all parts to be heated, allowing automated changeover from part to part. This type of automation will enable operators to minimize equipment downtime and improve productivity by loading all operating parameters at one time. Two other automated processes equipped on the InductoForge are an incremental temperature compensation feature and a billet “standby” control function. The incremental temperature compensation feature automates the billet temperature by incrementally adjusting the modules to maintain the optimal billet target temperature. This automation allows the system to control the billet exit temperature as conditions change throughout the day. The advanced "standby" control features automate the system's ability to minimize the number of rejected billets during short cell downtime. The automated "standby" process controls the power to each module to maintain the billet temperature profile through the coil line until the heater can be returned to normal operation. Automated Billet Purge Systems for Progressive Induction Heating Billet removal systems are used to automatically purge billets from an induction heating system upon completion of the production run. These systems are designed to integrate into the same general envelope of the induction heating system to conserve floor space and come in various lengths according to the overall length of the induction system. One example that is available is the patented BPS (Billet Pushout System) from Clinton Machine. This integrated solution is a flexible system, typically sized for a range of billets processed by the induction heater. When activated, the purge system will push out the remaining billets in the induction coil line and allow the heating process to continue until the last billet is extracted. The system logic and sensors monitor the extraction progress and instruct the billet heater to power down each induction inverter as it is cleared.

Figure 7. BPS (Billet Pushout System) fromClintonMachine, an Inductotherm Group company Some advantages of utilizing an automatic billet removal system include: • Automatically purge heating coils of remaining billets at end-of-run. • No need for "dummy billets" or other manual means of clearing billets from coils. • Reduce downtime and changeover time between billet runs – greater daily throughput. • Increased employee safety. • Floor space-saving design. • Flexible design- can be expanded as induction line length increased. • Offset mounted overhead storage chamber for ease of coil removal for maintenance and change out. Bar End Heating Automation The process of bar end heating refers to heating the end of a bar or series of bars for a forging operation. For processes that heat small diameter bars or low production rate systems, the operation tends to be more of a manual process, with operators loading & unloading bars. As process conditions change, such as increased cycle times, large bar heating applications, lack of forging operators or increased product requirements, the process can be made more efficient thought the use of automation.

Figure 8. Bar -end heating automation

FIA MAGAZINE | FEBRUARY 2021 35