Special Heating Equipment for extra large Workpieces

With the FAG HEATER5000 TAKRAF now has a powerful induction heating device for larger workpieces weighing up to a maximum of 5 000 kilograms. Smaller workpieces weighing up to 2000 kilograms that were previously heated using FAG HEATER1200 can now be heated much more quickly using the new device. This produces a wide variety of applications.

One of TAKRAF‘s newest product areas is the development of roll crushers and the associated gearboxes. These gearboxes comprise large and heavy components such as gears that weigh up to 5000 kilograms. TAKRAF has always used conventional FAG inductive heating devices that are suitable for workpieces weighing up to 1200 kilograms for heating their smaller workpieces. Since these devices are not able to heat the large gearbox components, TAKRAF needed a new heating device with considerably more power.

The local Schaeffler sales engineer forwarded the inquiry from TAKRAF to the specialists responsible at the Global Technology Network. Schaeffler engineers in the business unit Service and Application Engineering then designed a device that can generate sufficient electric power required for such large components – the FAG Heater5000. To ensure the heating process is carried out safely and evenly, the brand new Delta T control system technology was used. Two magnetic sensors simultaneously measure the workpiece inside and outside on two measuring points in order to monitor the temperature level and reduce it automatically if the maximum permitted difference in temperature is exceeded.

In addition to the Delta T control system with 2 sensors described above, the FAG HEATER5000 has two heating options controlled by setting the temperature (1 sensor) and the time. These are used for components with which there is no risk of changes in the structure during the  heating process (e.g. rolling bearings with large radial clearance or thin-walled workpieces).