1.RM-2000-XL controlled atmosphere sealed box-type multi-purpose furnace production line
| Serial number | project | Specifications and Data Description | |||||||||
| 1 | Multipurpose furnace production line | RM-2000-XL production line | |||||||||
| 2 | Loading size | 1500X900X1050 (length X width height including material tray) | |||||||||
| 3 | Applicable heat treatment process | Gas carburizing, carbonitriding, tempering, protective atmosphere bright quenching, cleaning, tempering | |||||||||
| 4 | Equipment capacity | Rated temperature | 950℃ | ||||||||
| Maximum one-time furnace loading capacity | 2000 kg (including tooling and materials) | ||||||||||
| 5 | production methods | Uninterrupted continuous production | |||||||||
| 6 | Equipment labeling terms | Chinese English | |||||||||
| 7 | Heat treatment process material | Low alloy carburized steel; some medium carbon alloy steel, etc. | |||||||||
| 8 | Carburized layer depth range | 0.3-5.0 mm | |||||||||
| 9 | Workpiece surface condition | Before heat treatment | Dry, clean and oil-free | ||||||||
| After heat treatment | No oxide scale, tempered color | ||||||||||
| 10 | Device color | Epoxy high temperature: deep golden blue/black/white/made according to the color code requirements provided by the user | |||||||||
| 11 | Power supply conditions | 3-phase, 380V±10%, 50Hz | |||||||||
| 12 | control voltage | 220V、50Hz | |||||||||
| 13 | Equipment installed capacity (111 configuration) (406 KW) |
multipurpose stove | washing machine | High temperature tempering furnace | Material truck | ||||||
| heating | Oil tank | motor | control | heating | motor | heating | motor | motor | |||
| 170 | 36 | 38 | 2 | 45 | 15 | 90 | 5 | 5 | |||
| 14 | Type of use atmosphere | Nitrogen, methanol, enriched gas, ammonia | |||||||||
| Methanol + enriched gas supply system: (maximum installed capacity of a single main furnace) | |||||||||||
| Nitrogen | 99.995% 8 m³/cd 100 mbar DN25 | ||||||||||
| Methanol | Industrial level 4.0 L/h 600 mbar DN10 | ||||||||||
| Enriched gas | propane | Industrial grade no free moisture Total sulfur content <10mg/m³ 0.6 m³/h 100 mbar DN15 |
|||||||||
| 15 | When carbonitriding, use an inlet | Ammonia Industrial level 0.2 m³/h 50 mbar DN15 | |||||||||
| 16 | Multipurpose Furnace Safe Nitrogen | Nitrogen 99.995% 23 m³/cd 100 mbar DN25 | |||||||||
| 17 | Multipurpose furnace front room protection | Nitrogen 99.995% 1 m³/cd 4 bar DN25 | |||||||||
| 18 | Constant open fire and fire curtain gas | Liquefied gas Industrial level 0.3 m³/h 50 mbar DN25 | |||||||||
| 19 | Electrical implementation standards | IEC and related national standards | |||||||||
| 20 | Other relevant national standards | JB/T7710-95,5050.4155,113455049:GB/T9451.9450.9452 | |||||||||
| Device name | Controlled atmosphere sealed box multi-purpose furnace |
| Device model | RM-2000-XL |
1.Equipment structural features
1.Overview
RM-2000-XL series controlled atmosphere sealed box-type multi-purpose furnace is a flexible and changeable heat treatment equipment with carburizing as the main process. It is an equipment that completes heating, carburizing, quenching or cooling in the same closed furnace body.
2.Technical Parameters
2.1 Basic parameters
| Effective working size(LxWxH) | 1500x900x1050mm(Including tray height) |
| Operating temperature | 780~930°C |
| maximum temperature | 950°C |
| Heating capacity at 700°C | 1360 kg/h |
| Maximum loading capacity (gross weight) | 2000 kg (including tray and rack) |
2.2 Electric energy parameters
| Heating/motor voltage | 380V士10%50HZ |
| control voltage | 220V |
| Empty furnace heating time | ≤2.5H |
| Total equipment power | 247KW |
| Furnace heating power (single unit) | 170KW |
| Quenching oil tank heating power (single unit) | 36KW |
| Motor installed power (total for a single furnace) | 41KW |
2.3 Temperature and control
| Number of control areas | zone 1 |
| Number of set points | 4 points (heating room main control, over-temperature, safety, oil temperature) |
| Thermocouple | K graduation |
| Heating control method | SCR phase shift trigger, self-tuning PID adjustment control |
| Furnace operation control method | PLC control: automatic, manual |
| Furnace operation visual monitoring method | Color touch screen displays equipment operating status |
2.4 Furnace characteristic parameters
| Temperature control accuracy | ≤+-1°C |
| Temperature uniformity in work area | (860°C/930°C)+-5°C |
| Furnace surface temperature rise | ≤Room temperature +55°C (both sides) |
| Furnace no-load power | ≤40KW·h has been raised to 880°C and kept warm, and gas has been supplied |
| To a full load of parts | Enter the cold workpiece into the furnace (furnace internal temperature 880°C), heat it to 930°C for no more than 4 hours, and cool it from 920°C to 700°C for no more than 2.5 hours. |
2.5 Quenching oil tank
| Quenching oil tank volume | 15.0m³ |
| Oil tank operating temperature | 50~150°C |
| cooling capacity | 170 KW/h |
| When quenching at 700°C under full load | After a quenching cycle is completed, the oil temperature can return to the set value, and there is an oil level prompt and an oil shortage alarm device. |
2.6 Atmosphere consumption parameters (single unit)
| Methanol | (Industrial level) | 600mbar | 4.0L/h |
| Enriched gas | propane | (Industrial level) | 100mbar | 0.3m³/h |
| Constant open fire and fire curtain gas | Liquefied gas | 28mbar | 0.4m³/h |
| Ammonia | Industrial level | 500mbar | 0.3m³/h |
| Front chamber protective nitrogen | 99.5% | 5mbar | |
| safe nitrogen | 99.5% | 100mbar | 5m³/h |
| Cooling water consumption | 3-4mbar | 2.0m³/h |
2.7 Installation parameters
| Basic dimensions of furnace appearance (LxWxH) | 6100X3600X5500mm |
| Total stove weight | 26,000Kg |
| working height above ground | 1200mm |
3. Structure description
3.1 Furnace structure
3.1.1 The air-tight furnace body consists of a heating chamber and a quenching chamber
3.1.2 The front room is a quenching room with a vertical furnace door driven by a motor for the entry/exit of workpieces. It is sealed with the furnace body.
3.1.3 There is a vertical door in the middle for heat insulation to divide the furnace body into two rooms: the heating room and the quenching room. The middle door is driven by a motor.
3.1.4 The workpiece is automatically transported from the quenching chamber to the heating chamber by an internal drive mechanism installed in the quenching upper chamber. After the process is completed, the internal drive automatically transports the workpiece from the heating chamber to the quenching chamber.
3.2 Heating chamber
3.2.1 The heating chamber lining is made of lightweight anti-carburization refractory bricks and high-quality insulation materials. The muffle and bottom rail are made of silicon carbide. The radiant tubes used are connected in parallel. When one radiant tube is damaged, it will not affect the power supply of other units.
3.2.2 In order to ensure strong circulation of furnace gas and good heat transfer, a centrifugal circulation fan made of heat-resistant alloy is installed on the top of the heating chamber. The circulation fan passes the protective atmosphere through the furnace bottom and workpiece to complete the circulation.
3.2.3 The furnace wall on the rear side of the heating chamber is equipped with an oxygen probe, a fixed carbon sheet analysis device, a rear observation hole and a heating chamber material tray detection device.
3.2.4 On the top of the heating chamber, there is a single-core temperature control couple and a double-core couple for safety control and recording. The top is also equipped with a device for placing samples.
3.3Quenching chamber
3.3.1 The front chamber is a quenching chamber, which consists of an upper chamber and a lower oil tank. The upper chamber is used for ventilation and quenching transition chamber. The lifting platform in the quenching chamber consists of two roller platforms, one upper and one lower. The upper platform is above the oil tank.
3.3.2 While the workpieces of the current furnace are still in the heating chamber or in quenching oil, the furnace is allowed to load another furnace of workpieces. Once the workpieces from the previous furnace are in the quenching oil, the internal feeding mechanism will automatically send the workpieces from this furnace into the heating chamber.
3.3.3 The driving device of the feeding mechanism on the quenching lifting platform is outside the quenching chamber. It drives the internal driving mechanism through a reducer to realize the transmission of the workpiece in the front and rear chambers.
During oil quenching, the lower platform is immersed in quenching oil. The quenching oil is vigorously stirred and circulated by agitators installed on both sides of the oil tank to ensure that the product after quenching has small deformation. The quenching oil is heated by electric heating elements installed on the side.
3.3.4 Cool under the protection of static protective atmosphere, and the workpiece is on the lifting platform. The side walls and top of the quenching chamber are equipped with cooling fin tubes that pass into the quenching oil.
3.4 Measurement and control equipment
3.4.1 All electrical appliances are installed in an independent control cabinet, and the cables can be connected from below or from the side
3.4.2 The temperature of the heating chamber is measured by three nickel-chromium-nickel silicon thermocouples. The compensation wires connect the three thermocouples to the main temperature control instrument, over-temperature control instrument and drip control instrument respectively. The main control temperature instrument with PID characteristics communicates with the operation screen.
3.4.3 Use Siemens programmable controller (PLC) to control carburizing, rate fire, exhaust gas ignition and all automatic incoming and outgoing materials. Flexible control, easy operation and safe use.
3.4.4 The gas supply system includes methanol, nitrogen, enriched gas, air and ammonia gas circuits. The solenoid valves, flow meters, hand valves and pressure detection switches of each gas circuit are installed on a gas supply rack to facilitate the process. control.
3.4.5 In order to better track the transfer process in the furnace, a touch screen is installed on the control cabinet to simulate the status of the furnace.
3.5 Safety device
3.5.1 If the power supply or protective gas supply fails, the furnace will automatically be filled with nitrogen and purified.
3.5.2 If the transfer action in a furnace cannot be completed within the specified safety time, an alarm will be issued.
3.5.3 The conveyor chain in the furnace can only operate when the exhaust port of the quenching chamber is ignited.
3.5.4 If the quenching oil is over-temperature or the agitation system fails, the oil will stop heating and an alarm will occur.
3.5.5 The entrance/exit door of the furnace is equipped with an electronic ignition burner and a fire curtain detection system. The front door can only be opened when the fire curtain is ignited normally.
2. Temperature and carbon potential control system
1 Overview
The heating chamber temperature and carbon potential control system of the controlled-atmosphere sealed box-type multi-purpose furnace consists of a touch screen, intelligent instrument, PLC, phase-shift trigger thyristor, high-power transformer and heating element. The heating of the oil tank in the front chamber consists of a temperature control meter, contactors and heating elements. The cooling of the oil tank consists of an oil temperature control meter, an oil circulation pump, a solenoid valve and a plate heat exchanger.
2.Control characteristics
2.1 The heating furnace system is composed of 2604 meter, main control thermocouple, over-temperature thermocouple, phase-shift trigger thyristor, high-power transformer and radiant tube. The 2604 instrument controls the temperature loop by the set process program. Under the calculation and adjustment of PID parameters, the analog output signal is sent to the thyristor to achieve precise temperature control.
2.2 The carbon potential control system consists of a 2604 meter, main temperature control, marathon oxygen probe and air supply solenoid valve. The main control temperature and oxygen probe signals are directly input into the 2604 meter.
2.3 The control of quenching oil temperature consists of Fuji temperature control meter, oil tank temperature control thermocouple, oil tank over-temperature thermocouple, oil stirring, oil level, oil cooling system and AC contactor. The heating conditions for quenching oil are that the oil level cannot be lower than the lower liquid level and cannot be higher than the upper liquid level, the oil stirring must be turned on, and there must be no over-temperature alarm. Oil cooling is in the case of quenching. When the oil temperature exceeds the set value of 5C, the cooling system automatically works to perform cyclic cooling of the oil temperature.
2.4 The temperature, carbon potential and quenching oil temperature of the heating chamber are connected to a Yokogawa paperless recorder to record the process in the form of curves and data. The recorder is also equipped with over-temperature alarm signals for each temperature point and ultra-high carbon potential alarm signals. , participate in the control of temperature and carbon control.
2.5 The inner and outer surfaces of the cabinet are equipped with sealing devices. There is a switch device on the front door that is interlocked with the lighting in the cabinet. When the user opens the cabinet door, the automatic lighting in the cabinet allows the user to clearly observe and maintain the control components. Each component in the cabinet has clear signs. , all cable connections are laid in their respective PVC covered wire troughs, making the entire cabinet clear, clear and tidy. At the same time, in order to ensure the normal operation of the components in the cabinet, a special air conditioner for the electrical cabinet is installed on the side of the cabinet.
3. Parameters
3.1 Control cabinet parameters
| Control cabinet size | |
| length | 1600mm |
| High | 2100mm |
| Depth | 600mm |
| Device name: | Double tank double liquid cleaning machine |
| Device model | QXM-2000-XL |
1 Overview
The cleaning machine is used to degrease and dry the surface of the workpiece quenched with carburizing oil in a multi-purpose furnace. The main body of the equipment consists of a clean room and a dry
The drying chamber is composed of double cleaning chambers. The workpiece is soaked in warm alkaline water for degreasing in the clean room and cleaned by the lift swinging up and down.
2.Technical parameters
| Basic parameters | |
| Effective size (length x width x height） | 1500X900X1050mm height with material tray |
| Maximum load (including tooling and materials) | 2000kg |
| Operating elevation | 1200 mm |
| Working temperature of alkaline water and clean water | 50~90°C |
| Complete a cleaning | ≤45 minutes |
| Electric energy parameters | |
| voltage | AC380V±10% 50HZ |
| Heating voltage | AC380V±10% 50HZ |
| control voltage | AC220C/DC24V |
| total power | 60KW |
| Motor power | 27KW |
| Other parameters | |
| Alkali water tank volume | 18KW |
| Clean water tank volume | 15KW |
| Alkaline water heating power | 4.0m³ |
| Clean water heating power | 1.6 m³ |
3. Structural description
3.1 Shell structure
3.1.1 The cleaning machine consists of a spray chamber, an alkali tank and a clean water tank. The tank chamber is welded into an integral structure using ordinary carbon steel.
3.1.2 There is a lifting platform inside the cleaning machine, which is driven by a reduction motor and a chain drive pair.
3.1.3 The tank body is equipped with flanges and valves connected to various pipelines, and the liquid storage tank is equipped with a liquid level control device.
3.1.4 There is an insulation layer around the tank side.
3.2 Cleaning process
3.2.1 The workpiece is placed on the lifting platform. During the immersion cleaning process, the lifting platform is immersed in the cleaning liquid. To improve cleaning effect
The lifting platform is rinsed with air foam in the cleaning fluid.
3.2.2 During the subsequent spray cleaning process, the workpiece is on the lifting platform roller table. At this time, the lifting platform is in the "up" position
Set. The hot clean water is drawn out from the lower part of the main tank by a pump and sprayed at high pressure towards the workpiece from all sides. Clean the main tank and row
The gas hood is directly connected, the cleaning liquid vapor is discharged from the exhaust hood, and the liquid can flow back to the main tank freely.
3.2.3 The time of the entire cleaning process can be preset without restriction.
3.3 Spray system
3.3.1 Multiple sets of fixed sprinkler heads are arranged in the cleaning room to ensure that all workpieces in the effective area are sprayed and cleaned.
3.3.2 The spray pump is installed on the rear base of the cleaning room. Including necessary pipeline valves and pressure indicating instruments, etc.
3.4 Oil withdrawal system
3.4.1 Remove oil from the auxiliary tank cleaning fluid. As a standard configuration, an oil drainer is installed outside the cleaning machine casing.
3.4.2 The water inlet of the oil skimmer is connected to the oil skimming pump. The water outlet of the oil skimmer is connected to the cleaning tank, and is separated through the oil drainer.
The oil pollution should be manually discharged regularly, and the discharge port is located at the bottom of the oil skimmer.
3.5 Cleaning fluid heating system
3.5.1 The cleaning fluid is electrically heated, and the heating element is vertically inserted into the cleaning fluid from the upper side of the main cleaning tank.
3.5.2 The temperature of the cleaning fluid is controlled by a temperature controller.
3.6 Safety devices
3.6.1 All electric heating systems and transmission parts that may injure operators are equipped with protection and "warning" signs.
3.6.2 All power cables on the equipment are laid in pipe troughs.
3.7 Material drying system
3.7.1 This system ensures the smooth progress of the next process, reduces the time required for traditional air drying, and improves work efficiency.
3.7.2 The system is equipped with a high-power fan and an independent air drying and heating box to ensure the best use results.
| Device name: | High temperature tempering furnace |
| Device model | GHM-2000-XL |
1 Overview
The maximum temperature of the tempering furnace is 700℃. The lining structure of the tempering furnace adopts brick structure, and the heating element adopts electric heating element.
tube, in order to achieve temperature control accuracy for tempering, a circulating fan is installed on the top of the equipment to facilitate air circulation and ensure
Proven furnace temperature uniformity.
2 Technical Parameters
| Basic parameters | |
| Effective working area size (including material tray) | 1500X900X1050 mm (LengthXWidthXHeight) |
| Maximum one-time furnace loading capacity | 2000 kg (including tooling and tools) |
| Operating elevation | 1200 mm |
| maximum temperature | 650℃ |
| range of working temperature | 180~650℃ |
| Temperature control accuracy | ≤±2℃ |
| Effective working area temperature uniformity | ±5℃ |
| power supply | 3-phase 380V 50HZ control voltage 220V |
| heating method | Electric heating tube |
| Total electric heating power | 95KW |
| heating power | 90KW |
| Motor power | 5KW |
3 Structural description
3.1 Shell structure
3.1.1 Furnace shell and single-station heating chamber.
3.1.2 The heating chamber has a vertical steel front door for loading/unloading. The door is electric and sealed by its own weight.
3.2 Heating chamber
3.2.1 The bottom of the heating furnace is equipped with a passage for entering and exiting the furnace materials, which is easy to remove for maintenance and repair. Heating chamber side wall brickwork
3.2.2 In order to ensure strong circulation of the atmosphere in the furnace and effective heat transfer, a resistant air guide is installed in the metal air guide sleeve on the top of the furnace.
Thermal alloy circulation fan. This fan is driven by a motor mounted on the top of the furnace shell.
3.2.3 The circulation fan inhales the atmosphere passing through the workpiece and the bottom of the furnace, forcing it to pass through the back wall of the heating system between the back wall of the equipment and the heat shield and then to the bottom of the workpiece.
3.2.4 The powerful atmosphere circulation in the furnace ensures good temperature uniformity in the entire working area.
3.2.5 The electric heater is suspended vertically between the rear wall and the heat shield.
3.2.6 There is a heat shield between the workpiece and the heater to prevent the heating system from direct radiation to the workpiece. The heat shield is located vertically at the end of the roller conveyor and at a certain distance from the rear wall. The heat shield can be easily removed for maintenance and repairs.
3.3 Measurement and control equipment
The control instruments and programmable logic controller (PLC) are installed in a control cabinet on the side wall of the furnace. The power cord can be connected from above, below or from the side.
3.3.1 The furnace temperature is measured by a nickel-chromium-nickel thermocouple with a chromium-nickel protection tube, and the thermocouple is placed on the side wall. Compensation wires connect the thermocouple to the temperature controller.
3.3.2 The human-machine interface is placed on the control cabinet, which can perform heat treatment process programming and equipment status simulation display.
4 control system
Control features
4.1 The tempering furnace is controlled by temperature control instruments and power regulators to ensure temperature control accuracy.
4.2 The control signal of the tempering furnace is connected to the PLC of the controlled atmosphere multipurpose furnace to realize the loading and unloading of the material truck. 4.3 The temperature control system of the tempering furnace consists of Fuji temperature control meter, main control thermocouple, thyristor and electric heater. Another thermocouple in the furnace is used as a recording signal and connected to the recorder on the multi-purpose furnace control cabinet. The recorder is also equipped with an over-temperature signal to control the tempering furnace temperature and alarm signals.
4.4 Complete wiring from each power point and control system to one or more junction boxes, and all connectors are consistent with the connectors in the switch cabinet. Heated parts are coated with heat-resistant primer and topcoat, and pipe painting is implemented in accordance with standards.