Disc Part CNC Hardening Machine for Gears, Saw Blades & Disc Components
In the precision-driven realm of metal heat treatment for disc-shaped components, the Disc Part CNC Hardening Machine emerges as a specialized and high-performance solution, redefining surface hardening standards for parts like brake discs, clutch plates, gear discs, and flange discs. Engineered to meet the strict quality and efficiency demands of industries such as automotive, heavy equipment, and power transmission, this advanced equipment fuses the precision of CNC (Computer Numerical Control) technology with targeted induction hardening—delivering exceptional accuracy, consistency, and durability for disc parts critical to operational safety and performance.
Unlike general-purpose hardening machines that may struggle with the unique geometry of disc components (e.g., flat surfaces, inner/outer rims, and thin cross-sections), this CNC-driven system is tailored explicitly for disc processing. It features programmable motion controls that adjust the induction coil’s position, heating intensity, and dwell time with micron-level precision, ensuring uniform hardening across the entire disc surface — even for parts with complex grooves or asymmetrical designs. The machine’s specialized clamping system securely holds discs without causing deformation, while its integrated cooling module precisely regulates post-hardening temperature, preventing cracks and preserving the part’s structural integrity.
Its intuitive HMI (Human-Machine Interface) allows operators to program and store process parameters for multiple part types, enabling quick changeovers between batches — critical for manufacturers handling diverse product lines. Whether you’re manufacturing high-volume automotive components or low-batch precision industrial discs, this machine is a purpose-built investment that elevates your disc part quality, reduces rework, and enhances production efficiency.
- ZD 1500
- Three-axis control: rotation + vertical + horizontal
- Workpiece diameter up to 1500mm
- Workpiece height up to 900 mm
- Max horizontal travel: 800 mm
- Max vertical travel: 1100 mm
- Retractable tailstock with automatic self centering chuck
- Automatic tracking system for maintaining a constant gap between workpiece and sensors
- Automatic reset for tooth by tooth quenching
- Recommended power: 150KW
- Camera for easy monitoring of the quenching area
- Quick equipment installation
- CNC system
- User-friendly HMI (Human-Machine Interface)
This machine can also be used as a standard vertical scanning hardening machine.
Power Supply for Induction Heating
IGBT converter series equipped with DSP-based control systems
- High Digital Advantages：Digital control replaces over 70% of traditional electronic hardware. The software enabling command transmission, parameter regulation, operational control, and system protection delivers higher precision and more sophisticated functions.
- User-Friendly O&M Design：The integrated keyboard supports rapid and accurate diagnostics, covering the operating status of all electronic components and cooling systems. A series resonant circuits enable automatic tuning and eliminating the need for manual adjustment when replacing inductors.
- High Adaptability & High Power：With a quality factor (Q-Factor) exceeding 2, it offers strong flexibility, supporting various inductors (both single-coil and multi-coil configurations) while delivering maximum output power.
Core Specifications:
- Output power ranging from 10 kW to 500 kW
- Operating frequency spanning from 100 Hz to 100 kHz
Optional Configurations:
- Dual-output design, supporting manual or automatic switching functionality
- Frequency switching module (high/medium/low), enabling a standard operating frequency reduction of up to 50%
Standard Equipment for All Models:
- Supply transformer
- Chopper voltage regulator integrated with IGBT transistors
Control Systems
A specialized Software Department (SD) is solely responsible for the design and development of complete command and control systems for machines and processes.
- User-Friendly HMI：The SD focuses on creating intuitive human-machine interface (HMI) software, tailored for unskilled operators to ensure easy operation.
- Safe Operation：Throughout the design process, the SD prioritizes and guarantees safe operating conditions at all times.
Hardware Options
- PLC + Operator Panel, suitable for simple applications
- PLC + Axes Control Unit + Industrial PC, suitable for more complex and advanced machines
- PLC + CNC, suitable for machines with specific functions or multi-axis interpolation capabilities
Software Options:
- Programmable logic (PLC) software, always accompanied by comments
- Human-machine interface (HMI) softwares running on the Windows OS for industrial computers are designed according to machine types with dedicated softwares
- CNC-based applications utilize the ISO language
Control Levels
| Basic | Heating energy control and quenching shower flow control |
| Middle | Heating energy control, oscillation frequency, quenching shower flow, and quenchant temperature control |
| Advanced | Heating energy control, voltage control, current control, frequency control, quenching shower flow control, quenchant temperature control, and inductor collision detection |
| Custom | The number of control channels is selected based on the safety level requirements of the process and product. |
Cooling Systems
GSC Cooling System
GSC systems, designed based on machine power and process type, represent the optimal solution for ensuring proper cooling of electrical components.
A typical GSC system consists of the following components:
A typical GSC system consists of the following components:
- Stainless steel tank equipped with a minimum level sensor
- Water-to-water heat exchanger in stainless steel
- Main cooling pump made of stainless steel
- Magnetic flow sensors with on-board adjustable alarm set points
Optional Components
- Automatic shutdown function to reduce industrial water consumption
- Automatic antifreeze system and automatic anti-condensation system
- Automatic water conductivity detection system
- Additional pump for high-pressure inductor feeding
GLT Cooling System
Inappropriate quenching, particularly in hardening processes, often results in suboptimal metallurgical outcomes. Additionally, inadequate filtration of the quenchant mixture constitutes a critical factor that must be addressed to ensure proper machine operation and consistent process results.
The CLT systems, designed based on power supply specifications and process type, serve as the optimal solution for achieving proper workpiece quenching.
A typical CLT system comprises the following components:
The CLT systems, designed based on power supply specifications and process type, serve as the optimal solution for achieving proper workpiece quenching.
A typical CLT system comprises the following components:
- Stainless steel tank equipped with a level sensor
- Stainless steel cooling pump
- Water-to-water heat exchanger in stainless steel
- Stainless steel shower pump
- Automatic workpiece temperature stabilization system
- Automatic filtration system
Optional Components
- Additional magnetic filtration section
- Automatic pre-heating system based on a weekly schedule
- Automatic system for removing suspended oil
- Automatic quenchant mixture type selection system (applicable when two or more CLT systems are in use)
- Automatic shutdown function to reduce industrial water consumption
Get in touch right now for solutions meeting your specific needs!
headquarter
Zching Induction
Shanghai based development and research center
