For a production facility of luxury automobiles one of our customers required an integrated solution for the heating of bores during assembly. The specific project at hand concerns an automatic eight speed transmission, meaning we needed eight separate heating stations, integrated in the production line. Only the bores need to be heated, with as little depth penetration of the heat as possible. The teeth of the gears have been thermally toughened beforehand and this process should not be interfered with.
After performing several experiments, we have now engineered a solution using water-cooled mid frequency heaters – 230 V / 16 A – and have tested this on the actual parts. Each station heats one component of the gearbox using a custom-made coil. Gear wheels and synchromesh are mounted at respectively 170 °C in 60 seconds and 80 °C in 35 seconds. Very precise, just as we like it.
We have developed a 100% flexible system where heaters can be added, unplugged and exchanged. This enables the customer to adjust the setup should new models require a different strategy. For example, these automobiles may in the future be fitted with nine speed transmissions. The adjustment of the heating stations is a simple task, thus offering long-term maximum usability.
Our solution now does the job more accurately than the previously used low frequency method. It is not only more flexible and energy efficient, but also ensures quick and secure change-overs: The heating stations are equipped with quick release connections.