Quality Made in Germany. News for our Customers and Interested Parties. Version

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1 Quality Made in Germany News for our Customers and Interested Parties Version

2 Welcome to our Newsletter Dear customers and interested parties, With our customer newsletter, we are pleased to give you an impression of our business plan and of our work as well as to be able to inform you about news regarding our systems and converters. Since already more than 65 years, EMA has offered reliable and innovative concepts encountering growing interest on all international markets. Our target is to offer trendsetting solutions increasing the machine and access safety along with reducing the energy consumption of your systems. Get to know new product innovations and solutions we developed for you. Get to know us and read about successfully realized projects. Inform yourself about events on which you can meet us. According to the vision We want to influence the market, we have strategically re-orientated ourselves. Customers demands still form the basis for the customer orientation of EMA Indutec GmbH. The focus is definitively on intensive care, the extension of business relations and therefore the successful, constructive cooperation. The principle should enable us to strengthen customer relations continuously. We, therefore, support present inquiries or projects by joint customer visits. In that way, we are anxious to offer the right technical solutions at the right time. We value your requests and your feedback in order to meet your expectations even better in the future and to offer you selective support. Have we aroused your curiosity? Then I wish you on behalf of all EMA employees countless new impressions while reading and outstanding ideas in order to understand the future with EMA Indutec GmbH as a valuable business opportunity. Kind regards, Dr.-Ing. Matthias Barz CEO 2

Hardening, Annealing and Tempering Systems THREE TRACK HARDENING MACHINE Three track

hubs. The system disposes of one hardening and tempering station per treatment track.

The machine can be integrated into the respective production line. Fig.

3 Hardening, Annealing and Tempering Systems THREE TRACK HARDENING MACHINE Three track hardening machine for hardening internal gear and the tracks of constant velocity joint hubs. The system disposes of one hardening and tempering station per treatment track. Hardening of the work pieces can also be carried out under protective gas. The machine can be integrated into the respective production line. Fig. 3b: cross section joint hub Fig. 3a: three track hardening machine Fig. 3c: three track hardening machine 3

The machine disposes of two working stations working independently from each other, can be loaded/unloaded manually

4 Hardening, Annealing and Tempering Systems Vertical feed hardening machine Double-spindle vertical feed hardening machine of the series Lupus for milled cam shafts. The machine disposes of two working stations working independently from each other, can be loaded/unloaded manually but could also be integrated into a fully automated production line. Fig. 4a: vertical feed hardening machine Fig. 4b: vertical feed hardening machine Fig. 4c: cam shaft 4

Hardening, Annealing and Tempering Systems GRIPPER STAR SYSTEM Gripper star system of the series Vela for inductive calibrating and tempering of sliding

Further possibilities of use of the Vela: hardening, calibrating, (fixture hardening, hardening with minimum distortion) and tempering of other rotationally

5 Hardening, Annealing and Tempering Systems GRIPPER STAR SYSTEM Gripper star system of the series Vela for inductive calibrating and tempering of sliding sleeves and coupling bodies under protective gas atmosphere (therefore low scale). Loading takes place manually, alternatively also automatically. Further possibilities of use of the Vela: hardening, calibrating, (fixture hardening, hardening with minimum distortion) and tempering of other rotationally symmetric work pieces such as e.g. crown gears, gear rings, coupling bodies. Fig. 5a: sectional view of sliding sleeve Fig. 5b: gripper star system 5

Hardening, Annealing and Tempering Systems INDEXING TABLE HARDENING MACHINE Indexing table hardening machine of the series Aquila for hardening and tempering

According to the conveyor belts, the system can also be integrated into the production line.

6 Hardening, Annealing and Tempering Systems INDEXING TABLE HARDENING MACHINE Indexing table hardening machine of the series Aquila for hardening and tempering of single cams of passenger car and truck cam shafts. The system can be loaded manually or via an optionally available, fully automated loading unit. According to the conveyor belts, the system can also be integrated into the production line. Working stations of the 16-part turntable: loading, checking, hardening, quenching, tempering, additional cooling, unloading. Fig. 6a: indexing table hardening machine Fig. 6b: hardening section single came 6

Hardening, Annealing and Tempering Systems VERTICAL FEED HARDENING MACHINE Vertical feed

The standard machine is equipped with an automated loading.

system and transferred from the conveyor belt onto the indexing table via EMA CNC

A hardness test has been integrated into the system as special accessories. Fig.

7 Hardening, Annealing and Tempering Systems VERTICAL FEED HARDENING MACHINE Vertical feed hardening machine of the series Lepus for planet carriers. The standard machine is equipped with an automated loading. The work pieces are loaded respectively unloaded via in- and outlet conveyor of the system and transferred from the conveyor belt onto the indexing table via EMA CNC handling system. Also the storage of scrap parts is carried out via handling system. A hardness test has been integrated into the system as special accessories. Fig. 7a: hardening process planet carrier Fig. 7b: vertical feed hardening machine Fig. 7c: Hardening section planet carrier Fig. 7d: planet carrier 7

Hardening, Annealing and Tempering Systems IN-LINE HARDENING MACHINE

The cover and the shaft of the joint housing are hardened and tempered

Also joint housings with boring instead of the shaft can be processed with

The machine can be loaded / unloaded manually or could be integrated into

8 Hardening, Annealing and Tempering Systems IN-LINE HARDENING MACHINE In-line hardening machine for joint housings. The cover and the shaft of the joint housing are hardened and tempered with the hardening machine. Also joint housings with boring instead of the shaft can be processed with this system. Furthermore, work pieces can be treated under protective gas. The machine can be loaded / unloaded manually or could be integrated into a fully automated production line. Fig. 8a: In-line hardening machine Fig. 8b: joint housing Fig. 8c: hardening section joint housing 8

Due to its sold and proved technology, the machine can definitively cope with the rough practices in contract heat treatment shops.

9 Hardening, Annealing and Tempering Systems VERTICAL FEED HARDENING MACHINE Vertical feed hardening machine of the series Taurus. The vertical feed hardening machine is available for different work piece clamping lengths (300 mm, 1300mm, 1500mm, 2000mm, 3000mm and 5000mm). Due to its sold and proved technology, the machine can definitively cope with the rough practices in contract heat treatment shops. Also the high product variety in hardening shops could be covered with this machine. The basic machine can be equipped with numerous additional equipment such as e.g. indexing tables in different design (4 x 90 single or double stations), single or double tailstock in support bearing or turntable operation, double support bearing and protective gas supply and protective gas housings. Fig. 9a: cross section hardening zones of different work pieces Fig. 9b: vertical feed hardening machine 9

Hardening, Annealing and Tempering Systems EMA INDUTEC GMBH SUPPLIES HARDENING MACHINE FOR THE THREE GORGES DAM IN CHINA Presently, the worldwide biggest ship-lift is under construction at the Three

The power of the converter for 250 kw was calculated at a frequency of 4 khz. The frequency can be switched over to 10 khz for heat treatment of the also requested usual module sizes.

10 Hardening, Annealing and Tempering Systems EMA INDUTEC GMBH SUPPLIES HARDENING MACHINE FOR THE THREE GORGES DAM IN CHINA Presently, the worldwide biggest ship-lift is under construction at the Three Gorge Dam in China. The drive of the ship trough is carried out via four gear rings moving along a 113 m high toothed rack. The power of the converter for 250 kw was calculated at a frequency of 4 khz. The frequency can be switched over to 10 khz for heat treatment of the also requested usual module sizes. Furthermore, a new hardening head transformer for adaption of the EMA-Indutec supplied a hardening machine for heat treatment of these toothed racks being especially designed for tooth gap hardening of the rack segments as well as being suitable for a later use regarding standard production. Therefore, EMA Indutec designed the so far biggest big ring machine (in portal design) for track and single tooth hardening. The single segments of the toothed rack are put on separate work piece locating fixtures and the single teeth are hardened in single tooth - tooth gap system converter - inductor had to be developed being able to transmit the expected currents. A new inductor concept had to be developed for the module size with a total tooth depth of 140 mm and for the requested hardness depth of 6-8 mm based, however, on the design of the well-known single tooth inductors. The required process was the so-called tooth-gap-hardening during which the ground is circumferentially hardened whereas the tooth tip itself should have an unhardened area. process. The energy supply is carried out by an EMAconverter of the latest generation, a TIV 2-D. Fig.10b: cross section of ring type gear Fig. 10a: hardening machine for ring type gear 10

Hardening, Annealing and Tempering Systems ONE OF THE BIGGEST INDUCTION HARDENING MACHINES IN EUROPE HAS SUCCESSFULLY BEEN COMMISSIONED Since the end of the year 2011, one of the biggest vertical

11 Hardening, Annealing and Tempering Systems ONE OF THE BIGGEST INDUCTION HARDENING MACHINES IN EUROPE HAS SUCCESSFULLY BEEN COMMISSIONED Since the end of the year 2011, one of the biggest vertical induction hardening machines in Europe has been operated with an energy supply of EMA Indutec. This machine is a vertical hardening machine for shafts with a diameter of up to 1000 mm and a length of up to eight meters. The machine has been designed by a Lohnhärterei and built under their own direction. Motivation for this investment was to be able to carry out a vertical, inductive heat treatment with minimal distortion of longitudinal shafts for wind energy systems close their manufacturer. Until now, the shafts had occasionally to be transported to the USA for an inductive heating and of course, to be transported back. An EMA-converter TIV-2D 3K800 has been chosen as energy supply being able to cover a frequency range between one and three khz. With an output power of up to 800 kw it allows material-dependent hardness depth of up to approximately 15 mm. Adaption of the alternating current (AC) converter to the planned inductors takes place via a transformer module enabling an operation of one-coil to threecoil heating coils without any problems. In order to limit the transmission losses regarding this 8 m long vertical travelling distance, the inductors are directly connected to the outputs of the EMA HK-transformers being placed on a stable and travelling carriage. The high-voltage connection between transformer and energy source is realized via respectively large, flexible coaxial cables. Commissioning phase: the hardened acceptance shaft had a length of eight meters at a diameter of 395 mm. The material was 42CrMo4 and the hardness depth was ten millimeter. Fig. 11: vertical hardening machine for shafts up to 8 m 11

Applications INDUCTIVE HEAT TREATMENT UNDER PROTECTIVE GAS More and more often operators have to face the problem of avoiding a time-intensive cleaning and/ or additional treatment of scaled

The only remaining solution therefore is to carry out the complete hardening process under an atmosphere protecting against oxidation.

12a: heating in air (left) and under protective gas (right) FIXTURE AND PRESS HARDENING In order to reduce time-intensive and expensive rework at already hardened surfaces, EMA Indutec intensively

12 Applications INDUCTIVE HEAT TREATMENT UNDER PROTECTIVE GAS More and more often operators have to face the problem of avoiding a time-intensive cleaning and/ or additional treatment of scaled functional surfaces caused during heat treatment especially regarding work pieces of increasing value. The only remaining solution therefore is to carry out the complete hardening process under an atmosphere protecting against oxidation. Therefore, EMA Indutec has focused on this problem during the last year and has developed different procedures to carry out heat treatment processes completely under protective gas atmosphere. Fig. 12a: heating in air (left) and under protective gas (right) FIXTURE AND PRESS HARDENING In order to reduce time-intensive and expensive rework at already hardened surfaces, EMA Indutec intensively and successfully occupied itself with fixture hardening in connection with inductive heating and subsequent inductive tempering in the last years. In cooperation with several customers worldwide, a number of processes on EMA systems have been integrated into their production lines. Fig. 12c: cut through calibration unit with inductor and quench Fig. 12b: calibration unit with inductor and quench 12

EMA - Converter Technology INNOVATIVE USE OF A DIGITAL EMA-CONVERTER AT A CABLE MANUFACTURER Tests at a wire heating system have shown that the throughput could be increased by a multiple with a

13 EMA - Converter Technology INNOVATIVE USE OF A DIGITAL EMA-CONVERTER AT A CABLE MANUFACTURER Tests at a wire heating system have shown that the throughput could be increased by a multiple with a power coil supplied by one converter. The temperature of the wire to be heated was increased from room temperature to approximately 700 C on a short distance of approximately one meter. Regarding a wire diameter of 3 to 6 mm, a Conclusion: With a new EMA-converter disposing of nine outputs and only one mains supply, all nine outputs are separately controllable. Wires with different diameters can be heated at the same time. The customer has worked with this system for nearly one year without any disturbances and has ordered further systems. maximal throughput of 100 kg/h per wire has been reached. EMA sets new standards in the converter technology With a converter newly developed according to a customer request with a power of up to kw at a frequency of 125 khz as well as an output voltage of V, EMA sets new standards in the converter technology. With this record-braking power spectrum, EMA positions itself on the technological top of modern converter technology. Fig. 13: 2 Megawatt converter type TIV2-D 13

14 EMA - Converter Technology State-of-the-art IGBT Converter Technology Channel furnaces Copper Nonferrous heavy metal Power: kw Frequency: Hz Power: Frequency: 20 2 Hardening, annealing and tempering Power: Tooth systems Bar steel Axles & Shafts kw Frequency: khz 14

EMA - Converter Technology designed for all kinds of Inductive

low energy consumption Low reactive power requirement by constant

dosage and reproducibility by high process capability Simplest

15 EMA - Converter Technology designed for all kinds of Inductive Applications Heating Shrinking Bonding/Soldering Coating/Drying Strip & Wire Power: Melting kw Crucible melting furnaces Laboratory furnaces Vacuum furnaces 250 kw...30 khz Forging/Forming Blocks/Slugs Billets Rods/Tubes Tube end Rails heating Power: Frequency: 0,2...4 khz Your Benefits High energy efficiency and efficiency by low energy consumption Low reactive power requirement by constant cos phi Short process times by high energy density Precise energy dosage and reproducibility by high process capability Simplest operation as well as controlling and regulation of different parameters Easy integration into most different production systems kw Frequency: 0,2...8 khz 15

Quality Management The Quality Management System of EMA Indutec was checked, certified and further developed by an external certifier in July 2003.

16 Quality Management The Quality Management System of EMA Indutec was checked, certified and further developed by an external certifier in July The certificate is audited yearly by an external certification authority. Internal audits are carried out yearly by the QM Team of EMA Indutec in order to monitor the effectiveness of the QM System. Deviations detected during internal audits are corrected and possible improvement suggestions are integrated into the QM System. MAINTENANCE OF THE CERTIFICATE ISO 9001:2008/ VDA 6.4 A certification according to the Standard ISO 9001:2008 und VDA 6.4 is standing for a worldwide quality standard and is the valid award for a Quality Management System according to international standards. The regular, yearly verifications of the Management System are associated with the issue of the certificate in the year Subsidiary Our subsidiary EMA Induction Technology (Beijing) Co., Ltd. was established in This subsidiary is supporting the EMA location in Germany and ensures a global care for customers being able to use our products and services worldwide. EMA Induction Technology Beijing Co., Ltd. Shahe Industrial Area, Changping District Beijing , China Phone: +86 (10) Fax: +86 (10) ema@ema-indutec.com.cn 16

After Sales Service An all-round-after-sales-service-package Regarding a pro-active service, EMA Indutec has extended the product range of its different services.

17 After Sales Service An all-round-after-sales-service-package Regarding a pro-active service, EMA Indutec has extended the product range of its different services. Besides a non-destructive analysis and system testing via thermal imaging camera, we furthermore offer our customers training in our premises. Additionally, EMA In case induction systems should be modified in sections or even completely, the EMA Retrofit is the right choice for you. We will carry out the modification and overhaul of your EMA induction hardening system with qualified staff from all departments. offers a Call-Service for spare parts, ensuring a high flexibility at low costs and a pro-active maintenance with maintenance seal increasing the lifetime and the We offer all our customers the best possible, individual solution for their different requirements. Contact us! reliability of operation remarkably. During regular customer visits by experienced and highly qualified service technicians, the product range is introduced to the responsible persons for production and maintenance and the respective benefit is worked out. Our most important aim is to find the best possible service for customers requirements in a personal discussion. This increases the lifetime and the availability of systems as well as it reduces and avoids unplanned production stops. You can reach our Service-Hotline 24 hours a day, 365 days a year in case of machine stops and in case Fig. 17: EMA 24-h Service Hotline +49 (0) of any technical questions. 17

18 Trade Fairs and Events 2015 May th 22th May IFHTSE Congress- Heat treatment and surface Engineering I-Mestre 25th 29th May metalloobrabotka - Equipment, Devices and Tools for the metalworking Industry rus-moscow June nd 04th June A3TS Congress Heat Treatment and Surface Treatment F-Zénith de St. Etienne 16th 20th June GIFA - International Foundry Trade Fair with technical Forum G- Düsseldorf 16th 20th June Thermprocess - International Trade Fair and symposium for Thermo Process Technology G- Düsseldorf 16th to 17ht June International VDI Congress Drivetrain for Vehicles G- Friedrichshafen October th 30th October Heat Treatment Congress G-Cologne November th 19th November seminar in Heat Treatment G-Ludwigsburg 18

Integrated Total Solutions OUR SERVICE FOR YOU AT A GLANCE Since more than 65 years, we are at your disposal as your competent partner from planning over design up to final production and supply!

19 Integrated Total Solutions OUR SERVICE FOR YOU AT A GLANCE Since more than 65 years, we are at your disposal as your competent partner from planning over design up to final production and supply! Frequency converter for induction systems We produce induction heating systems for Surface hardening Tempering and treating Hardening and calibrating Customer-specific solutions and special systems Converter and systems from one hand Frequency converter in IGBT-technology with performance from 20 kw up to several kw with a working frequency from 50 Hz up to 100 khz Hardening under protective gas Fixture hardening Shrinking on After Sales Service Efficient and competent Service-Center with ensured and worldwide long-term system service Optimum maintenance structure Longstanding spare parts stocking Process trainings at site Worldwide 24/7 Top-Service with Hotline Experienced and highly qualified Service Technicians We are happy to assist you with any query. Feel free to contact us: sales@ema-indutec.de Tel. +49 (0) Fax +49 (0)

EMA Indutec GmbH Petersbergstraße 9 D-74909 Meckesheim Tel.

20 EMA Indutec GmbH Petersbergstraße 9 D Meckesheim Tel. +49 (0) Fax +49 (0) sales@ema-indutec.de Imprint Newsletter by EMA Indutec GmbH Editor: A. Lorenz, J. Kern, W. Goy Photos: W. Goy, C. Pinter, J.Pahlke Layout / Design: A.Lorenz EMA Line Customer Newsletter E model-, program- and technical changes and errors reserved.

Induction Heating. Jean Callebaut, Laborelec. 1 Introduction Physical principles Induction Installations... 5

Induction Heating. Jean Callebaut, Laborelec. 1 Introduction Physical principles Induction Installations... 5 Induction Heating Jean Callebaut, Laborelec 1 Introduction... 2 2 Physical principles... 2 2.1 Electromagnetic induction... 2 2.2 The Joule-effect... 3 2.3 Penetration depth... 3 3 Induction Installations...