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State-of-the-art surface hardening and tempering plant successfully operational

At the end of March, ITG Induktionsanlagen GmbH, one of the leading suppliers of complete induction solutions, handed over the latest generation of surface hardening and tempering equipment to LSV Lech-Stahl Veredelung GmbH ready for operation. This plant, which is individually tailored to the customer's requirements, is intended for the third production site in Meitingen, Germany, which went into operation in 2019. The system allows complex treatment processes for surface hardening with the subsequent tempering of the surface layer for alloyed and unalloyed steels. The main dimensional range is in the range of up to 50 millimeters in diameter with a length of up to 8.2 meters can be performed.

This order was challenging for ITG Induktionsanlagen as general contractor, as supply and services included not only the process plant but also the interface clarification, i.e. a turnkey plant including cooling systems and finishing equipment. In addition, the highest standards of environmental protection, energy efficiency and safety were demanded.

Special emphasis has been placed on the reproducibility of process control with high repeat repeatability. Because of its configuration, the system can process a wide range of dimensions and offers tremendous flexibility and thus a platform for broadband applications by a quick adaption of the matching transformer and the induction tools to the load side. Depending on the desired hardening depth, different application frequencies are available.

The high quality requirements of the customer have been assured by an optimised process control system. numerous recipe-based warning and fault limits guarantee optimal adaptation of the quality assurance systems to the respective product. In addition, an integrated fault simulation enables the easy and quick verification of the quality assurance elements.  Detailed process data monitoring and archiving enable the production processes to be traced.

Important corporate guidelines of LSV concerns environmental protection, energy efficiency and safe working conditions. These principles were part of the project requirements. The system was equipped with state-of-the-art air extraction and cleaning equipment including an integrated fire protection system. In addition, special emphasis was placed on the use of energy-efficient components in the design. Engineered safety features, precise and comprehensible instructions and handling in compliance with the EC machinery directive, could achieve a very high level of safety for the plant operator.

Both companies expressed their considerable contentment with the execution of this project. "The aim was also to meet the demanding requirements of CQI-9 for inductive heat treatment systems for our customer and achieve the greatest flexibility for current and future products," explains Michael Manthey, Head of Project Management ITG Induktionsanlagen. On the LSV side, project managers Hans Schramm, plant manager/QA manager, and Robin Reich, the maintenance team leader, highlighted the design and process possibilities of the new production line and emphasized the constructive and effective cooperation.