The XK100 Induction Heating Machine for combination pliers is a digital and intelligent device specially designed for the head quenching of hardware tools. It adopts the core technology of DSP digital series resonant power supply and is integrated with the Siemens PLC control system to achieve precise and controllable heating parameters.
The equipment features three core advantages: 7-fold safety protection, a high-efficiency cooling system, and flexible customizable fixtures. It is suitable for the production of multiple types of pliers, helping enterprises reduce costs by 40%, improve product quality by 99%, and increase efficiency by 50%.
- 40% Energy Saving: Compared with traditional equipment, power is only consumed during the heating phase, resulting in an annual electricity cost saving of over 100,000 yuan;
- Precise Quality Control: Equipped with Siemens PLC and touch screen, the heating parameter accuracy reaches ±0.5%, and the consistency of the quenching layer depth is up to 99%;
- Multiple Safety Protections: 7 protection functions including over-temperature, water shortage and over-voltage protection, achieving zero safety accident risk;
- Flexible Customization: Suitable for more than 10 types of pliers such as combination pliers, diagonal pliers and long-nose pliers, with fixture replacement completed in only 15 minutes;
- High-efficiency Cooling: Combined with water chiller and plate heat exchanger, the volume is reduced by 30% and the cooling efficiency is improved by 25%.
The heads of combination pliers and diagonal pliers are key stress-bearing parts. They require induction heating quenching to improve hardness (HRC58-62) and wear resistance, extending the service life of the tools by more than 3 times.
Common machining materials include high-carbon steel (e.g., 45# steel) and alloy steel (e.g., Cr12MoV). However, traditional processes are prone to problems such as uneven heating deformation, oxide layer residue, and quenching layer depth fluctuation, which directly lead to a scrap rate as high as 5%-8%.
5 Major Production Bottlenecks of Outdated Equipment
- Low Efficiency: Long heating cycle (30 seconds per piece → only 15 seconds with the XK100), resulting in a monthly production gap of over 20,000 pieces and delayed orders;
- Unstable Quality: Large errors caused by manual parameter adjustment, with a quenching layer depth deviation of ±0.3 mm and a high scrap rate;
- Excessively High Energy Consumption: The energy consumption of traditional resistance heating is 1.67 times that of the XK100, with an annual power consumption of over 300,000 kWh;
- Potential Safety Hazards: Lack of intelligent protection, prone to equipment burnout due to overheating and electric shock accidents caused by leakage;
- Difficult Maintenance: Aging components of outdated equipment lead to a long maintenance cycle (7 days → only 48-hour response with the XK100).
Closed-Loop Control from Blank to Finished Product
The XK100 enables efficient operation of the entire process: Loading → Parameter Setting → Induction Heating → Quenching & Cooling → Online Inspection → Unloading. Core processes are precisely controlled by a digital system, eliminating human-induced errors.
1. Loading and Fixture Adaptation
- Customized Quick-change Fixtures: For different types of pliers (e.g., 15°/20° head angle of diagonal pliers), fixture replacement requires no tools and can be completed within 15 minutes;
- Automated Docking: Supports linkage with existing production lines to realize unmanned loading, improving efficiency by 30%.
2. Core Control of Induction Heating
- Equipment: DSP digital series resonant power supply (output frequency: 20-30 kHz) + Siemens PLC S7-1200;
- Parameter Control: Temperature tolerance ±5ºC, power adjustment range 10%-100%. The heating status is monitored in real time, with automatic compensation for voltage fluctuations;
- Risk Control: Built-in temperature sensor triggers immediate shutdown in case of overheating to avoid workpiece burnout.
3. Quenching and Cooling System
- Equipment: Combined plate heat exchanger and water chiller;
- Process: Precise control of quenching fluid flow rate (tolerance ±0.5 L/min). The cooling rate is matched to material characteristics to eliminate deformation;
- Advantages: No cooling tower required, covering an area of only 0.8 m2, with noise ≤60 dB.
4. Online Inspection and Unloading
- Equipment: Hardness tester;
- Process: Inspects quenching layer depth (tolerance ±0.05 mm) and surface hardness. Data is uploaded to the system in real time, and non-conforming products are automatically rejected;
- Value: Reduces the scrap rate from 5% to 0.8%.
| Indicator |
XK100 Performance |
Traditional Equipment Performance |
Improvement Amplitude |
| Energy Consumption Reduction Rate |
40% |
- |
40% |
| Single Piece Processing Time |
15 seconds |
30 seconds |
50% efficiency improvement |
| Quenching Depth Deviation |
±0.05mm |
±0.3mm |
83% precision improvement |
| Defect Rate |
0.8% |
5% |
84% reduction |
| Maintenance Cost |
5,000 CNY/year |
15,000 CNY/year |
67% cost saving |
Case Study: Upgrade Record of a Hardware Tool Factory in Guangdong
The factory originally used 2 sets of old-fashioned induction heating machines, with a monthly output of 150,000 pieces, a scrap rate of 6%, and an annual electricity cost of 280,000 yuan. After replacing them with 2 sets of XK100 in 2023:
- Monthly output increased to 220,000 pieces, meeting the demand of overseas orders;
- Scrap rate dropped to 0.7%, reducing monthly losses by 12,000 yuan;
- Annual electricity cost decreased to 168,000 yuan, saving 112,000 yuan.
Application Scenarios: Hardware tool factories (mass production), old production line upgrading (localization replacement), small-batch customization (multiple types of pliers), high-precision machining of high-temperature alloys.
Parameters and Configuration
| Parameter Item |
Specification Value |
| Model |
XK100 |
| Type |
DSP Digital Series Resonant Power Supply |
| Rated Voltage |
AC380V 50Hz |
| Rated Power |
120kW |
| Power Adjustment Range |
10%-100% |
| Power Control Precision |
±0.5% |
| Output Frequency |
20-30kHz |
| Protection Class |
IP54 |
| Working Mode |
Constant Voltage/Constant Power Switching |
| Cooling Method |
Forced Water Cooling |
| Floor Area |
1.2m×0.8m×1.5m |
| Serial Number |
Name |
Specification Model |
Origin |
Manufacturer |
| 1 |
IGBT Module |
300A |
Germany |
Infineon |
| 2 |
Rectifier Bridge |
MDC-300-150 |
Changzhou |
Ruihe |
| 3 |
PLC Controller |
Siemens S7-1200 |
Germany |
Siemens |
| 4 |
HMI Touch Screen |
Siemens KTP700 |
Germany |
Siemens |
| 5 |
Filter Capacitor |
2700uf/1200V |
Zhejiang |
Ningbo Herong |
| 6 |
Resonant Capacitor |
170nf/2500V |
Zhejiang |
Antai Electric |
| 7 |
Water Chiller |
Customized Model |
Guangdong |
Local Supplier |
| 8 |
Plate Heat Exchanger |
Customized Model |
Jiangsu |
Local Supplier |
Audited Supplier 
){kind=link}