Other Products / Services #7257804

Unlock the power of relaxation and durability with our induction stress relieving services. Using advanced technology, we alleviate internal stresses in metal components, enhancing their stability and longevity. Whether it's weldments, castings, or machined parts, our precise process ensures uniform heating and controlled cooling, resulting in improved performance and reduced risk of deformation. With our expertise and state-of-the-art equipment, we deliver fast and reliable stress relieving solutions tailored to your needs. Experience superior quality and durability with our induction stress relieving services today.

The VEL PH/PW series provides a highly versatile tool for preheating, stress relieving, hydrogen bake out and post weld heat treat in a variety of pipe diameters and flat plate.

Features:

• Designed for continuous heating operation 
• Equipped with rugged heavy duty components to tolerate harsh working conditions 
• Very  Compact and portable (could be easily mounted on any   trailer / trolley & moved by forklift / crane) 
• All safety trips / interlocks incorporated including sensing the temperature of critical power components of the equipment 
• Efficiency of the power source is better than 95%
• Low Voltage design makes it very safe to use at site
• Inductors are specifically designed keeping in  mind  ease of operation  required.
• Thermal Profile Controller, Data Logger & Paper Chart Temperature Recorder is integrated as required.
• Provides uniform rapid heating in plate and pipe applications
• Reduces set-up time and time -to temperature 

An induction heater for pre and post-weld heat treatment service utilizes electromagnetic induction to heat metal components uniformly. In pre-weld treatment, it aids in stress relief, reducing cracking risks, and enhancing weld quality. Post-weld, it ensures uniform heating for tempering, annealing, or stress relieving, improving material properties and weld integrity. This efficient heating method minimizes distortion and improves productivity, offering a reliable solution for industrial welding operations requiring precise heat treatment.

Induction Shrink Fitting Services

Trouble Disassembling Components? Let Our Expertise Solve It for You.

What is Induction Shrink Fitting?

Induction shrink fitting is a specialized process used to assemble or disassemble components by utilizing the principle of thermal expansion and contraction. In this process, induction heating is employed to heat one component (usually the outer component or the housing) to a specific temperature, causing it to expand. Once the desired temperature is reached, the inner component (typically a shaft or a smaller part) is inserted or removed while the outer component is still hot.

This method is commonly used in various industries such as automotive, aerospace, manufacturing, and machinery for assembling gears, bearings, pulleys, shafts, and other components that require a precise and strong fit.

Services we provide:

• Induction Shrink Fitting of: 
• Roller Bearing
• Inner Race
• Bush
• Sleeve
• Pinions
• Rotor Shaft Assemblies
• Turbine blades
• Pressure Tube in PHWR

The VEL HardTech series represents cutting-edge induction hardening, annealing, and tempering systems tailored to meet the evolving needs of the heat treatment industry. 

We offer complete turnkey solutions that include an advanced Induction Power Source, CNC/PLC control automation, high-frequency transformer, and custom-designed coils tailored for specific jobs. Our solutions also feature job-specific scanning (horizontal or vertical), single-shot fixtures, and rotary or indexing tables. They seamlessly integrate with semi or fully automated job loading and unloading facilities, ensuring that the system fulfils your hardening requirements effectively.

Features:

• Manual and automated program settings with multiple pre-programmed recipes.
• Intuitive touch panel interface with comprehensive process monitoring features.
• Quick connect coil system facilitates easy replacement of induction coils.
• Efficient load/unload and part centering system for manual or automated operations.
• Designed for in-line integration, ensuring short lead times and seamless workflow.
• Reliable mechanical solutions ensure high system availability and productivity.
• Precise process control leads to excellent results and increased productivity.
• Energy-efficient power supply unit (>95% efficiency) reduces energy costs.
• Flexible design accommodates a wide range of part sizes for versatility.
• Modular unit for easy servicing and maintenance, minimizing downtime.

Technical specification:

The Induction Hardening System (VEL/IH Series) is specially designed for Induction Hardening of components on turnkey basis complete with > Induction Power Source > CNC/PLC based servo motor driven Vertical/Horizontal Scanner > Water circulating & Cooling system and Quenching system > Semi-Automated/ Fully Automated job loading/unloading facility (optional)

VEL i-Braze Series

VEL i-Braze series comprises of state-of-the-art induction brazing systems designed to meet the evolving demands in the field of metal joining.

It includes an advanced light weight and portable high frequency transformer and joint specific custom designed coils together known as brazing tong. The coils can be easily fitted on and removed from the transformer.

The brazing tong can seamlessly integrate with robotic arms or any automation as per client’s requirements

Standard Features

• Application based customization
• Wide range of output power ratings and frequencies range
• Tolerates abrupt discontinuities in the coil circuit (e.g., sudden insertion, removal, or geometric changes of the workpiece).
• Withstands severe disturbances on incoming power lines.
• Integrates safety-oriented design features to prevent electric shock hazards associated with the brazing tong during operation.
• Features an automatic machine trip mechanism in the event of accidental contact between the brazing tong and the workpiece, ensuring the integrity of both the machine and workpiece.
• Safety Interlocks for Water pressure, temperature, flow, etc.
• Power Factor > 0.90
• Output regulation> 90%
• Intuitive user interface
• Simple and effective indications

TECHNICAL SPECIFICATION

VEL i-Braze System (Type VEL/BR/#) consists of Converter Inverter Microcontroller based Control, Protection & Interlocks Output Transformer & Inductor Water Cooling & Circulating System (Optional) Holding Fixture (Optional)  XYZ Slide for the Brazing Tong Assembly (Optional)

Induction forging process is energy efficient, rapid / instant heating process as it provides superior productivity, consistent quality, flexibility and reliability. 

VEL ForgeTech series is specially designed and manufactured for heating metal in forging, rolling, stamping extrusion, upsetting and other forming applications to obtain desired shape in Presses, Bending Machines, Forming machines, etc on turnkey basis. They are designed to heat any dimension of billets, bars, blocks, slabs etc in full or partially in materials as diverse as Steel, Stainless Steel, Brass, Bronze, Aluminium, Copper, Titanium, Silver, etc and their alloys

INDUCTION HEATING POWER SOURCE

Induction Heater , Thyristor / IGBT based, of varying power capacities ranging from 400 kW to 1600 kW consisting of Inverter modules auto tuned to Resonant Frequency ranging from 1 to 20kHz, incorporating Microcontroller (µC) based electronic controls, Protection/Trip circuits, Interlocks etc, Output Matching Transformer, Inductor Assemblies etc.

CONTROL AND FEEDBACK SYSTEM

PLC based control system & SCADA for automated system & process. All alarms generated and machine / process parameters  displayed / controlled from HMI on Control Panel / SCADA.

Non-contact pyrometers are used to measure the part temperature to achieve precision temperature control, to maintain temperature consistency, feedback for hold modes, option to reject job for over/under job temperatures etc.

HEATING STATION

The induction coil is completely contained within the steel shell and is isolated from the job with a refractory coating. There is no chance of hot slag or other materials from the furnace contaminating the room. 

LOADING/ UNLOADING & FEEDING SYSTEM

Semi-Automated/ Fully Automated job loading/unloading facility are available, such as Vibratory, magazine, step, or bowl feeders, V-flight and other conveyor feeders to move billets into drive position, Pneumatic or hydraulic horizontal pusher, tractor drive, pinch roller drive or walking beam arrangement for moving job through the inductor, High-speed conveyors to rapidly deliver the hot job to press operator or robot pick up point, etc

VEL MeltPro series is a comprehensive range of furnaces for melting all non ferrous metals and precious metals like silver, gold etc.

This melting equipment has a long life and provides an accurate temperature measurement. 

Features:

• Power regulation (10 – 100%) 
• Advanced software driven solid state converters.
• Temperature controller – works with a thermocouple probe or optional IR pyrometer.
• Fast acting electronic interlocks for safe and reliable operation. 
• Automatic / Manual tilting control.
• Custom models with different capacities can be designed.

Techincal Specification:

VEL MeltPro serries consists of Converter Inverter Control, Protection & Interlocks Output Transformer Coil / Furnace Water Cooling & Circulating System.

Ensure Consistency Every Time with our Induction Brazing Services.

What is Induction Brazing? 

Induction brazing is a joining process that uses electromagnetic induction to heat and melt a filler material (brazing alloy) without directly melting the base metals being joined. This method is commonly used to create strong and durable joints between two or more metal components.

Here's how the induction brazing process typically works:

Preparation: The metal parts to be joined are thoroughly cleaned and prepared to ensure proper bonding.

Brazing Filler Material: A brazing filler material, often in the form of a pre-placed paste, powder, or wire, is applied at the joint area between the metal parts.

Induction Heating: An induction coil is placed near the joint area, and an alternating current passes through the coil, creating a rapidly changing magnetic field. This magnetic field induces eddy currents within the metal parts, generating heat due to resistance. The heat is concentrated at the joint area, where the brazing filler material is located.

Brazing Temperature: The induction heating raises the temperature of the joint and the brazing filler material to the brazing temperature, typically above the melting point of the filler material but below the melting point of the base metals.

Capillary Action: As the brazing filler material melts, it wets the surfaces of the base metals and is drawn into the joint by capillary action.

Cooling and Solidification: Once the brazing process is complete, the joint is allowed to cool and the brazing filler material solidifies, forming a strong and durable bond between the metal parts.

Induction brazing offers several advantages:

Precision Heating: Induction heating allows for precise and localized heating of the joint area, minimizing heat-affected zones in the surrounding areas.

Fast and Efficient: The induction heating process is fast, efficient, and energy-saving compared to other heating methods like flame brazing.

Clean and Controllable: Induction brazing produces clean and controlled joints without the need for flux, reducing post-processing requirements.

Versatility: It can be used for joining a wide range of metals and alloys, making it suitable for various applications across industries such as automotive, aerospace, electronics, and manufacturing.

Quality Joints: The controlled heating and precise melting of the brazing alloy result in high-quality joints with excellent strength, corrosion resistance, and structural integrity.

Overall, induction brazing is a reliable and effective method for creating strong and durable joints in metal components, offering benefits in terms of precision, efficiency, cleanliness, versatility, and quality.

Services we provide:

Induction Brazing of:

• Copper parts for compressors.
• Copper components of transformers.
• Brass components.
• Submersible pump rotors.
• Ring cable lugs.
• Aluminium component joints.
• Soldering of brass components.
• Steel components joints.
• Brazing of storage water heater Elements.
• Diamond tipped cutting tools.
• Carbide tipping of cutting tools.
• Optical Frame Brazing.
• Fuel pipe Brazing.
• Vacuum brazing of critical components.
• Brazing stainless steel orthodontic parts.
• Brazing of stainless steel to Brass.
• Rocker Pins.
• Hydraulic Hose.

During the process of finish grinding of clinker, lot of heat is generated inside the cement mill. The heat generated in excess has to be dissipated so that mill discharge temperature is kept at a desired level (around 90-120°C) to prevent the deterioration of the quality of cement. The increase in temperature beyond 125°C leads to dehydration of gypsum which changes the property of setting of cement. The decrease in temperature below 90°C leads to wet clogging of gypsum and the cement strength is affected.

Internal water cooling in a cement mill serves to maintain the mill outlet temperature constant at preset values.

VEL Cement Mill Water Spray System is the advanced method of temperature control in cement mills which results in enhanced cement quality.

Application

VEL Cement Mill Water Spray System comprises of complete set of pumps, valves, spray nozzles. instruments etc & all relevant accessories, assembled as one unit making it user-friendly and easy to install.

Water Cooling in the Cement Mill is accomplished by injecting and evaporating water at the outlet / inlet end of the mill. The water vapour is removed from the mill together with the ventilation air, which must be so ample that the temperature does not drop below the dew point anywhere in the pipes, dedusting filter, etc after the mill.

The system ensures precise control of temperature in both the chambers of cement mill by regulating the volume of injected water through motorised control valves. The design of the injection nozzles and the compressed air used for atomization gives a very good turn down ratio in the entire range of water flow regulation. When the water injection is disconnected, compressed air purging keeps the injection nozzles clean. The system may be interfaced and operated through your existing PLC/DCS or may be provided with a standalone control panel.

VEL Cooler water spray system comprises of complete set of skid mounted pumping & valve train system along with spray nozzles & relevant accessories. All necessary instruments, control valves etc are provided. All closed loop controls, sequence of operation, alarms & Safety interlocks are provided. The system may be interfaced to your existing PLC/DCS or may be provided with a standalone control panel.

DESIGN CRITERIA

The purpose or application, dimensions of the Grate Cooler, the height of the clinker bed, the overall gas flow, the gas temperature, the clinker temperature profile, number of nozzles needed and the height at which the lances are to fixed in the cooler compartment, the degree of cooling required put together determines the type of is spray system to be used, that is:

Compressed air atomized water spray system

Spillback water spray system

Fogjet / Multicone water spray system

Flatjet water spray system

Application

In Cement Industries, VEL Grate Cooler Water Spray System is used for cooling the vent gas for any of these purposes:

To increase the efficiency of ESP by reducing fugitive dust emission.

To reduce the power consumption of the vent outlet fan.

To maintain a slightly more negative pressure at vent outlet thus contributing in reducing fugitive emission.

To reduce the temperature so that the upstream conveying equipments could be designed for lower temperatures thus reducing the capital cost.

To cool the clinker directly so that the inlet temperature to cement mill is within controllable limits.

To control the depth of the clinker bed both to avoid grate burn-out due to low bed depth, and to avoid stalling the cooler fans due to excessive bed depth.

To limit fluctuations in the secondary air temperature as this can upset the kiln temperature profile and adversely affect clinker quality.

Principle Of Operation

In VEL Grate Cooler Water Spray System, the temperature of the stream of gas / clinker is cooled in three stages:

Heating of the injected liquid to the boiling point temperature corresponding to the system pressure.

Conversion of part of the liquid into a gaseous state by evaporation of the liquid.

Superheating of the evaporated liquid.

We can also provide Grate Cooler Water Spray System especially for Direct Cooling of Clinker bed. This is normally required when the cooler is operated above its designed capacity.

We design, manufacture, supply to achieve your ultimate goal.

We are offering a comprehensive range of Microcontroller based Electronic Control, Induction Heater (VEL/BH series) specifically designed and manufactured for mounting of shrink fitting components such as Bearings, inner races, gears, pinons, couplings, etc.