A steel bar manufacturer faced a common challenge: producing small, medium, and large bars (14mm to 80mm) on the same site, but a single induction line could not handle all diameters without quality loss. Yuantuo proposed a three-line solution, each optimized for a specific diameter range.

Engineering explanation

The solution segmented the diameter range into three groups: 14-28mm (small), 30-60mm (medium), and 65-80mm (large). Each line has its own power supply, coil design, frequency range, and cooling capacity. This allows independent operation and prevents the compromises required by a single universal line.

Real order case (based on Yuantuo engineering standard – configuration used for multiple domestic and export projects)

– Customer: Steel processing plant (China, 2022-2023)
– Workpiece: Carbon and alloy steel bars φ14-80mm, length up to 6000mm
– Line 1 (φ14-28mm): IGBT quench 350kW/6000Hz + IGBT temper 200kW/4000Hz; output 1 ton/hour; closed cooling tower 30+20T
– Line 2 (φ30-60mm): KGPS quench 500kW/2500Hz + 200kW/3000Hz; KGPS temper 200kW/2000Hz + 250kW/1500Hz; output 2 tons/hour
– Line 3 (φ65-80mm): KGPS quench 500kW/1500Hz + 500kW/1000Hz; KGPS temper 400kW/1000Hz + 200kW/1200Hz; output 3 tons/hour
– Customer pain point: Existing single line caused surface overheating on small bars and core under-heating on large bars; frequent coil changes caused downtime
– Solution: Three independent lines with quick-change recipes stored in PLC; shared raw material and finished goods handling
– Result: Monthly output 800-1000 tons; hardness uniformity ±2 HRC across all diameters; changeover time between product families reduced to zero (parallel production)

Complete system solution

steel bar Q&T line includes: induction power supply, resonant capacitor bank, water-cooled induction coils (quench + temper), inclined U-shaped roller conveyor, infrared pyrometer (Raytek), Siemens PLC, spray quenching system with filter, closed cooling tower, and automatic loading/unloading.

Call to action

Do you process a wide range of bar diameters? Request a feasibility study from Yuantuo for a segmented line configuration tailored to your product mix.

Website：yuantuoinduction.com
WhatsApp：+86-15226757228
Email：yuantuo38@gmail.com