In traditional heat treatment, distortion of components post-treatment is the historic problem that generates additional costs due to rejected parts and additional machining to correct these problems. Seco/Warwick, winner of Intelligent Development Award, has developed an innovative UniCase Master system, which can replace outdated heat treatment methods by utilizing a fully automated system with a new method how gearbox components are loaded and quenched using the single-flow case hardening system.
The system, simply defined, continuously loads parts that individually enter the heat treatment process, and when complete, enter 4D quench for precision cooling that is key to eliminating component distortion. The transfer systems in and out of the furnace are designed to maintain the integrity and surface quality of each component, even at high volumes.
“When we initially approached the problem of part distortion in the production of gearboxes, we realized that the conventional methods of material handling and quenching actually caused the majority of distortion problems,” says Maciej Korecki, VP, Vacuum Heat Treatment Furnaces, Seco/Warwick. The researchers reimagined the entire heat treatment process from a new perspective. It was this idea, previously thought impractical, of a single flow vs. a mass flow in high volume operations where they found the key to solving the problem. Coupled with full automation and a precision heating and cooling control system, the company created a practical approach that can be applied in every industry that is focused on superior quality and profitable operation.
The fully automated UniCase Master system offers users a system technology that achieves repeatable results for high volume heat treatment, eliminating human interventions throughout the process. A sophisticated control system proven throughout thousands of installations controls all options within the system complete with pre-programmed cycles for the Seco/Warwick signature technologies including FineCarb vacuum carburizing and tempering and isothermal quenching. A comprehensive technical service package offering is provided, Seco/Predictive, an advanced control option that can detect potential failures before they occur.
It reduces the distortion of gears in continuous production that challenges conventional case hardening methods with a single flow, precision case hardening system for high volume manufacturing.
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