Product Description
Paijin Vacuum gas quenching furnace is a vacuum furnace consisted by furnace body,heating chamber,hot mixing fan,vacuum system,gas filling system,vacuum partial pressure system,electric control system,water cooling system, gas quenching system, pneumatic system,automatic furnace feeding trolley and power supply system.
Application:
It is suitable for quenching treatment of materials such as die steel, high-speed steel, stainless steel, etc; solution treatment of materials such as stainless steel, titanium and titanium alloy; annealing treatment and tempering treatment of various magnetic materials; and can be used for vacuum brazing and vacuum sintering.
Characteristics:
1. High cooling speed: by using high efficiency square heat exchanger, its cooling rate is increased by 80%.
2. Good cooling uniformity: Air nozzles are evenly and staggered set all around the heating chamber.
3.High Energy Saving: Its air nozzles will automatically close in heating process, makes its energy cost 40% less.
4. Better temperature uniformity: its heating elements are evenly set all around the heating chamber.
5. Suitable for various process environments: Its heating chamber's insulation layer is made by composite hard insulating layer or metal insulating screen.
6. Less work pieces deformation, higher produce rate and lower usage cost.
7. Smart and easy for process programming, stable and reliable mechanical action , automatically, semi-automatically or manually alarming and displaying the faults.
8. Frequency conversion control gas quenching fan, optional convection air heating, optional 9 points temperature survey, partial pressure quenching and isothermal quenching.
9. With whole AI control system and an extra manual operating system.
Standard model specification and parameters:
| Model |
PJ-Q557 |
PJ-Q669 |
PJ-Q7711 |
PJ-Q8812 |
PJ-Q9916 |
| Effective Hot Zone LWH (mm) |
500*500*700 |
600*600*900 |
700*700*1100 |
800*800*1200 |
900*900*1600 |
| Load Weight(kg) |
300 |
500 |
800 |
1200 |
2000 |
| Maximum Temperature(ºC) |
1350 |
| Temperature control accuracy(ºC) |
±1 |
| Furnace temperature uniformity(ºC) |
±5 |
| Maximum Vacuum Degree(Pa) |
4.0 * E -1 |
| Pressure raise rate (Pa/H) |
≤ 0.5 |
| Gas quenching pressure (Bar) |
10 |
| Furnace structure |
Horizontal, single chamber |
| Furnace door opening method |
Hinge type |
| Heating elements |
Graphit heating elements |
| Heating chamber |
Composition structure of Graphit hard felt and soft felt |
| Gas quenching flow type |
Vertical alternating flow |
| PLC & Electric elements |
Siemens |
| Temperature controller |
EUROTHERM |
| Vacuum pump |
Mechanical pump and roots pump |
| Customized optional parameters |
| Customized optional ranges |
| Maximum temperature |
600-2800 ºC |
| Maximum temperature degree |
6.7 * E -3 Pa |
| Gas quenching pressure |
6-20 Bar |
| Furnace structure |
Horizontal,Vertical, single chamber or multi chambers |
| Door opening method |
Hinge type, Lifting type,Flat type |
| Heating elements |
Graphit heating elements, Mo heating elements |
| Heating chamber |
Composed Graphit felt, All metal reflecting screen |
| Gas quenching flow type |
Honrizontal alternating gas flow;Vertical alternating gas flow |
| Vacuum pumps |
Mechanical pump and roots pump; Mechanical, roots and diffusion pumps |
| PLC & Electric elements |
Siemens;Omron;Mitsubishi;Siemens |
| Temperature controller |
EUROTHERM;SHIMADEN |
Standards:
DIN 17052 - 1 "Heat treatment furnaces - Part 1: Requirements for temperature uniformity"
EN 60519 -2 "Safety in electroheat installations - Part 2: Particular requirements for resistance heating equipment"
AMD2750D "AEROSPACE MATERIAL SPECIFICATION"
NFPA86D "Standard for Ovens and Furnaces"
GB/T 16876 "Vacuum test standard for double wall equipment"
GB/T 10066.1 " Test methods for electroheating and electromagnetic processing installations"
GB/T 9452 "Testing Method For Working Zone Of Heat Treatment Furnace"
Hi,my friend, thanks for checking Paijin Vacuum furnaces. I will show you why our products are your best choose.
Technical advantages:
- Energy saving: By using our self-owned registered patented technology of energy saving, our furnaces saves 20%-40% energy than other brands in heating. Reduces muh cost.
- High Intelligent Control system:All our furnaces are equiped with our high intelligent control system, it can realize one button operation by the recorded data and record the processs in Computer.
- Advanced Voltage control technology, lower current in same power to avoid the melting of cables, and raise safety level.
Processes
Paijn vacuum furnaces are basically composed by Furnace body, heating system, vacuum system, gas recharge system and control&measure systems.
A standard vacuum furnace would able to used for the basic processes like:
Annealing
Tempering
Brazing
Sintering
Hardening
In Vacuum and Atmosphere conditon.
By adding some fuction parts, it will realize or strengthen its ability in
Carburizing
Debinding
Nitriding
Oil hardening
Low temperature difference brazing (≤±3ºC)
Hot zone materials:
Graphite Hot Zones
Graphite hot zones are long-lasting and can deliver excellent ROI. They are robust, economical to repair and incorporate hearth designs with high creep strength.
All-Metal Molybdenum Hot Zones
If your process is susceptible to graphite contamination, a molybdenum hot zone can meet your needs. Our moly hot zone elements feature a "double-U" profile which makes them easy to install and replace.
Custom Constructions
We offer custom hot zone construction such as graphite insulation with moly heating elements, for applications with unique requirements.
Payment terms and ordering process:
We accept paymen by TT:
20% TT in advance, 50%TT after confirmation of drawings and 30% TT after PSI but before loading on board
or 100% LC at sight.
Ordering Process:
Confirm user's technical specification requirement----Quotation with specification---confirm specification and other terms---sign contract--first payment or Issurance LC----Drawing confirmation----Manufacturing---Preshipment inspection and training---Shipment----field service like installation and commission(optional)---after sales service
Produce time and delivery schedules
According to different model and requirements about the furnace, It need about 3-8 monthes for the produce of the furnace.
After the finish of the furnace, User's representatives are invited to visit our factory and inspect the furnace in our factory.Meanwhile,we can supply 1-2 weeks free training courses for them in our factory.
After the pre-shipment inspection and final payment, we will arrange the shipping within one week.
Quality Control:
Quality is the spirit of the products, is the key point decide a factory's future.Paijin take quality as the most priority issues in our daily work.To ensure the good quality of our products, we paid much attention on 3 aspects.
- Most important: Human. Human is the most important point in every work. We have complete training courses for every new worker, and we have rating system to rate every worker to a level (junior, middle, high), different level workers are apponted to different jobs with different salary. In this rating system, it's not only the skills, but also rate in responsibility and error rate, executive power etc. By this way, workers in our factory are willing to do the best in his work.And strictly follows the quality management rules.
- Best materials and components: We only purchase the best materials on market, we know that saves 1 dollar in material would cost 1000 dollars in final. The key parts like electric components and pumps are all brand products like Siemens, Omron,Eurotherm, Schneider etc. For the other parts made in China, we choose the best factory in industry and signed product quality guranntee contract with them,to ensure every component every parts we use in the furnace is the best quality products.
- Strict Quality management: We have 8 quality check points in the processes of furnace producing, Examination in each check point is carried by 2 workers and 1 factory manager is responsible for it. In these check points, materials and components, and every aspects of the furnace are double checked to ensure its quality. At last, before the furnace leaves factory, it should be final checked with heat treatment experiments.
Packages and Shipping:
We have much experience in the packages and shipping, our furnaces are usually shipped by rail or by sea. Sometimes small parts my shipped by air. The main body will be fixed in the container by steel ropes and other parts will be packaged in wooden cases.
After sale service:
a. Quality Guarantee
We supply a guarantee period of 12 months reckoning from the date of commissioning of the furnace against all defects or failures due to faulty design, material, or workmanship. But within 18 monthes after the furnace is deliveried from our factory.
b. Backup support for provisioning of spares for 15 x years.
c. Technical Support:We supply 15 years free online technology support for our furnaces.
Sample quotation
Quotation No.:PJ220219A
Date:2022/02/19
1.Price and payment terms:
| Commodity |
Description |
Amount |
| Furnace |
With all necessary parts |
119000 USD |
| Tools for maintenance |
|
Included |
| Spare parts |
As listed below |
Included |
Payment terms: 30% TT in advance, 70% TT after PSI but before loading on ship or 100% LC at sight
Note:
a. Above price based on Fob Qingdao,China(INCOTERMS 2010)
b. Above price not including the service charges of field service (like Flight Ticket charges, Engineers salary, travelling charges etc.)
c. Charges of Buyer's inspection people should on buyers own account.
2.Manufacture time and Business schedule
a. Manufacture time: 4 months after we received the pre payment or L/C.
b. PSI time: Within 1 Week after we finished the manufacture.
c. Delivery time: Within 2 Weeks after PSI (pre shipment inspection) but after the receive of final payment(if payment by T/T).
3.Pre-Shipment Inspection
The representative of the buyer are invited to participate the PSI(preshipment inspection) at supplier's factory on their own cost before shipment, if the buyer cannot participate the inspection due to the epidemic or other reasons, pictures and videos of the inspection shall be sent to the buyer by supplier before shipment.
The preshipment inspection includes:
a. Basic inspection (cold test): the whole equipment is arranged reasonably, with good appearance, painting, no crack, no burr, color conforming to requirements, sealing inspection, inspection of purchased parts (motor, sensor, cylinder, electrical components, etc.), and correct wiring.
b. Dynamic performance detection: the stability of mechanical device action, the tightness of water and gas path, and the detection of gas circuit under pressure; Detect interlock and alarm system.
c. The preshipment inspection must be carried out in accordance with this document (main technical parameters), and meet the technical requirements of furnace temperature uniformity, maximum service temperature, pressure rise rate, ultimate vacuum degree, etc.
d. The equipment must be assembled and formed by the supplier. After the test run is completed and the preshipment inspection is passed, the equipment can be disassembled and transported to the supplier for installation and debugging.
4.After sale service
a. Quality Guarantee
We supply a guarantee period of 12 months reckoning from the date of commissioning of the furnace against all defects or failures due to faulty design, material, or workmanship. But within 18 monthes after the furnace is deliveried from our factory.
b. Backup support for provisioning of spares for 15 x years.
c. Technical Support:
We supply 15 years free online technology support for our furnaces.
5.Equipment Brief introduction
PJ-Q966 vacuum high pressure gas quenching furnace has the functions of vacuum gas quenching, vacuum tempering and vacuum annealing. It is mainly used for various vacuum heat treatment processes such as quenching, tempering, annealing, vacuum solid solution and so on.
The vacuum high-pressure gas quenching furnace has the following characteristics;
intelligent, high degree of automation, and one key operation of process operation can be realized.
adopt energy-saving patented technology, all air ducts are closed during heating and automatically opened during quenching. The heat loss in the treatment process is greatly reduced.
the workpiece has the advantages of good surface quality, small heat treatment deformation and good repeatability.
parts are interlocked during operation, with high safety.
6.Main Technical Parameters
| ITEMS |
Parameters |
| Type |
Horizontal, single chamber |
| Heating Zone Dimension |
900*600*600 mm (LWH) |
| Loading Capacity |
600 kg (not including the pallet) |
| Rated Power in Heating |
160kw (Max 80% output power) |
| Temperature control method |
Single zone,9 points measurement,temperature difference within 5 ºC |
| Power of quenching fan |
132kw(Max 70% output power) |
| Total Working Power |
≤150kW |
| Max Temperature |
1350 ºC |
| Work Temperature |
150ºC-600ºC for tempering;1000ºC-1260ºC for quenching |
| Accuracy of temperature control |
±1ºC |
| Heating elements |
High purity graphite heating tube |
| Thermal insulation material |
Integral graphite hard felt |
| Fixing mode of furnace lining |
Molybdenum pull rod |
| Hearth layout |
No wind resistance in horizontal direction |
| Heating time of empty furnace |
≤60 min to 1200ºC |
| Work Vacuum Degree |
≤0.1 PA |
| Vacuum pumping speed |
≤15 min to work vacuum degree |
| Pressure rise rate |
≤ 0.5 Pa/H |
| Gas Quenching Pressure |
10Bar |
| Partial pressure |
10-1000 Pa |
| Inert Gas |
N2,AR(≥99.999%) |
| Control mode |
Touch screen LCD + PLC+IPC+Program Control |
7.structure, Components, Spares
Single chamber vacuum high-pressure quenching furnace is composed of furnace body, energy-saving heating chamber, hot mixing fan, vacuum system, gas filling system, vacuum partial pressure system, electric control system, water cooling system, gas quenching system, pneumatic system, automatic furnace feeding trolley and power supply system.dd
During operation, the assembled workpiece is sent to the furnace through the automatic feeding trolley, then the furnace door is closed, and the whole heat treatment process such as vacuum pumping, heating, back flushing gas, quenching and tempering is controlled through preset programs.
7.1 Main BodyThe main machine body of vacuum furnace is a horizontal single chamber structure, which is composed of furnace shell, furnace door, heating and quenching chamber, air cooling device, water cooling system, water cooling electrode, safety device and other accessories.
7.1.1 furnace body and furnace door (produced by manufacturers with pressure vessel production qualification)
The furnace body and cover are of double wall water-cooled structure. The inner and outer walls of the furnace body are made of high-quality carbon steel, and the inner wall of the furnace body is coated. The water-cooled inner shell of the furnace body is coated with corresponding corrosion inhibitor to make it have good anti-corrosion ability.
The furnace shell is manufactured by a manufacturer with manufacturing qualification and provided with corresponding documents, which can ensure that the furnace shell and all materials exposed to vacuum environment can work reliably under the whole temperature, atmosphere and vacuum environment.
The lower part of the furnace body is provided with a furnace body support for placing the furnace body. The furnace body is strictly sealed and welded, and the test pressure meets the national standard.
The furnace door adopts pneumatic device, and the automatic opening and closing of the furnace door is realized through control action.The furnace door and the furnace body are connected by hinges. Bearings are installed at both ends of the hinge main shaft and a furnace door adjustment mechanism is set to adjust when the furnace door is found to sink after long-term use.
The sealing between the furnace body and the furnace door adopts the lock ring sealing structure, and the silicone lip sealing ring (special for high pressure and high vacuum) is installed in the groove of the furnace door flange to ensure the sealing of the vacuum furnace under negative pressure and pressurized air cooling. The opening and closing of the lock ring is pneumatic with double air cylinders, which can be opened and locked automatically. Multiple inclined plane self-locking is adopted between the furnace door lock ring and the furnace door, which is simple, safe and reliable; The locking ring has the function of safety locking.
The safety valve of furnace body is composed of mechanical safety valve and automatic vent valve, which works and is set independently.
The position and size of furnace vacuum system interface, water cooling electrode interface (stainless steel), instrument interface, inflation system interface and other interfaces can be reasonably adjusted according to Party B's purchased parts and previous experience.
For the user's use and upgrading requirements, reserve the vacuum pumping interface and inflation reserved interface of diffusion pump, and lock it with blind flange when not in use.
7.1.2 heating chamber
The heating chamber is composed of frame, thermal insulation layer, heating element, material table, closed heating and quenching device, etc. Of which:
The heating chamber is welded into a rigid whole with profiles, and the whole graphite hard felt thermal insulation material is laid in the outer frame.
The thermal insulation layer is composed of 60mm graphite composite hard felt.
The heating element is composed of high-purity graphite rod and insulating seal. The heater is evenly distributed along the insulation layer, which can ensure no deformation, long service life and uniform heating for long-term use. The structure design is reasonable and the surface thermal efficiency is high.
The uniform distribution of heating elements ensures the rapid and uniform heating of furnace temperature, no deformation after long-term use at high temperature, stable resistance value and simple and convenient maintenance. The heating elements are distributed circumferentially, so that the heating chamber has fast temperature rise speed, good temperature uniformity and long service life of the heating elements. Each group of heating elements can be disassembled separately, which is convenient for replacement and maintenance. Material table is composed of graphite hearth, graphite pillar and ceramic spacer embedded on the hearth.
The lower part of the furnace is equipped with transverse high-strength graphite material table and high-purity graphite column. The material table will not block the air nozzle during quenching, and the atmosphere is evenly distributed. Two longitudinal graphite table furnaces are inlaid with impervious carbon 99 porcelain triangle. Four rollers are installed at the bottom of the furnace liner. The whole furnace liner can move along the guide rail in the furnace shell to ensure the free expansion of the liner body. At the same time, the furnace liner can be pulled out for maintenance.
The closed heating and quenching system has obvious energy-saving and quenching uniform effect. The quenching air nozzle is automatically closed in the heating process to eliminate radiant heat loss. During quenching, the heat shield is automatically opened, and the opened baffle forms an air duct to guide the gas into the air duct evenly. The air inlet volume is large and uniform, and the deformation of the work piece is small. The patented quenching air nozzle is automatically closed during heating and opened during quenching without external mechanical action, reducing vacuum leakage points.
(option) the thermal circulation convection heating system is composed of vacuum water-cooled motor, high-temperature resistant CFC connecting shaft and fan blade. It can be used for convection heating in low-temperature state, shorten the time of vacuum radiation heating, improve the heat transmission speed of workpiece and reduce deformation. It can also be used for vacuum low-temperature tempering after quenching.
7.1.3 High pressure and large flow quenching system
The high-pressure quenching system is composed of vacuum large flow water-cooling fan, extrusion integrated copper high-efficiency heat exchanger, diversion air duct and programmed inflation and air replenishment system. In the system, the frequency converter starts the fan to drive the inert quenching gas. The gas forms an internal closed cycle through the diversion air duct, so that the high-temperature gas can be replaced quickly and evenly through the water-cooled heat exchanger, and the heat of the workpiece can be taken away instantly. The adjustment of gas quenching pressure can be realized by vacuum high-pressure stop valve, check valve, frequency converter, pressure sensor and control program.
System advantages:
- The integrated extruded copper fin tube is adopted, and the heat exchange effect is stable from beginning to end.
- It adopts the fan structure of German Epson, with large flow, uniform flow and small workpiece deformation
- Self closing air duct is adopted, with small heat loss and high furnace temperature uniformity
- The design of air duct is reasonable, and the power consumption of quenching fan is 55% of that of the same industry
- The structure can realize isothermal quenching
- The structure can realize vacuum tempering
7.2 vacuum system
The vacuum system consists of vacuum host, vacuum valve, vacuum pipeline and special vacuum gauge.
The vacuum unit is composed of mechanical vacuum pump + roots vacuum pump, vacuum pneumatic baffle valve, bellows, electromagnetic vent valve, pipeline, etc.
The vacuum valve adopts pneumatic vacuum pneumatic baffle valve. A filter collection device is installed between the furnace body and the roots pump, which is passed through the large diameter pipeline, which can not only improve the extraction speed, but also greatly improve the service life of the vacuum pump. The opening and closing of the valve are controlled by PLC and interlocked. In case of power failure, the valve will close automatically to ensure the vacuum degree in the furnace and avoid workpiece oxidation. In order to facilitate vacuum leak detection, a vacuum measurement interface is set above the mechanical pump and roots pump.
The vacuum measurement and control system is composed of digital display resistance vacuum gauge and gauge. The vacuum gauge can realize automatic range conversion and over range protection in the measurement process, and has many functions, such as setting control pressure, data output, fault alarm and so on.
7.3 recharge gas system
The recharge gas system consists of three parts: inflation system, pressure regulation system and safety valve. The inflation system is composed of large diameter vacuum fast charging ball valve (Taiwan stone), fine adjustment valve, flowmeter, inflation valve (automatic and manual) and pipeline accessories. The pressure regulation and control system is composed of pressure sensor and regulator. Can be used to achieve:
During heating, the partial pressure in the furnace is controlled (combined with the vacuum gauge). This device can be used to adjust and control the vacuum degree in the furnace and adjust the vacuum degree within the set range, so as to meet the process needs of special materials and prevent the volatilization of alloy elements due to too high vacuum in the furnace.
During cooling, the pressure in the furnace is adjusted and controlled to cooperate with the pressure sensor. When forced rapid cooling is required, open the automatic valve to fill the furnace with cooling gas. The inflation pressure is adjustable, and the functions of partial pressure and buffer can be realized.
7.4 electrical control system
The electric control system is composed of programmable controller PLC, man-machine interface system, thyristor voltage regulator, vacuum meter, voltmeter and ammeter, DC regulated power supply, air switch, contactor, relay, button, indicator light, etc., so as to realize the functions of power supply, control, recording, monitoring, alarm protection, etc. The full-automatic operation of vacuum furnace is realized by programmable logic controller (PLC). At the same time, it is equipped with a manual operating system for debugging and maintenance.
The system takes PLC as the operation control core to monitor the real-time state of the equipment. The operator generates output control through the input of and the judgment of the current state. The direct control is implemented by a large number of relays. The system is equipped with perfect safety protection functions through the system man-machine interface. When the equipment has abnormal conditions, such as water pressure, temperature, vacuum If the inflation pressure and other indicators or some parts are abnormal, the system will send an alarm on the touch screen and the alarm light at the same time, and display the current abnormal reason in detail. The equipment has perfect and reliable self-locking and interlock protection function during use to ensure that the equipment will not have accidents due to misoperation of operators.
The application of digital display vacuum gauge, pressure sensor and recorder enables the equipment to automatically judge the operating conditions according to the preset temperature curve, vacuum, pressure and other conditions. The operation of the control equipment can realize the automatic generation of heat treatment process, automatic process control, tracking and storage record of heat treatment process, and has the function of fault self diagnosis and monitoring.
7.5.1 measuring device
(1) Thermocouple (high pressure corundum tube)
1) Double core S-type thermocouple is used for temperature measurement in hot chamber, one core is used for temperature control, and the other core is used for recording and over temperature alarm. Thermocouples are evenly distributed in the heating chamber. Each thermocouple has a matching connector, "s" type compensation wire and mounting parts.
2) The thermocouple measures the temperature in the temperature zone of the corresponding equipment, realizes the real-time monitoring of the working process, and ensures the uniformity of the temperature in the furnace room during heating and insulation. The temperature is measured at 9 points.
3) The plug-in thermocouple is used to directly measure the core temperature of the workpiece and control it in linkage with the main control couple.
(2) Resistance vacuum gauge (protective tube of high pressure pneumatic valve)
It is used to measure the vacuum degree of the cold chamber in the furnace. Place vacuum gauges on the furnace shell and vacuum pipeline respectively to measure the vacuum degree.
7.5.2 control equipment
(1) Control system
It adopts German Siemens programmable controller. Programmable logic controller (PLC) has the advantages of reliable operation, simple operation and maintenance, strong expansibility and high integration. It can realize manual / automatic control of production process and programmable control of mechanical action. The system adopts programmable controller, which can make the reliability and process automation of the electrical system, realize evacuation, simplify the electrical schematic diagram, and make the debugging, overhaul and maintenance of the equipment more simple and convenient. Through the pre programmed program, it can realize the switching of manual and automatic control in the working process of the equipment, and improve the safety and Reliability.
(2) Temperature and pressure control
The temperature and pressure are controlled by program, the temperature control accuracy is ± 0.1%, and has the function of PID parameter self-tuning.
Furnace temperature uniformity ≤ 5 ºC. With 9-point temperature measuring device, the thermocouple adopts armored n-couple (double core).
(3) Selection requirements of low-voltage electrical components, reliable performance and long service life.
7.5.3 thyristor voltage regulator
The thyristor voltage regulator has the characteristics of high reliability, simple operation and convenient maintenance. The system outputs the heating power supply with low voltage and high current through the thyristor voltage regulator to improve the operation efficiency of the equipment and ensure the personal safety of operators.
7.5.4 display and recording equipment
(1) Display device
The electric control cabinet is equipped with an integrated workstation to display and control the operation status of each pump, valve and air-cooled motor in real time. The humanized interface design is intuitive, concise and convenient for operation.
(2) Recording equipment
The integrated workstation can record and store furnace temperature, vacuum degree, etc. The recording curve is clear, bright, reliable and easy to maintain, and the USB interface is configured for data backup and transfer. It ensures the integrity of recorded data and facilitates the recording, archiving and query of data.
7.5.5 electrical control cabinet
(1) An independent closed control cabinet is installed into all measuring and control devices. The fully open hinged door can fully enter the cabinet to maintain the lines and back instruments. The control cabinet is divided into operation, feedback, measurement and power output modules. Measuring, recording and control instruments are installed on the front of the panel. The control cabinet has interlocking protection functions such as over temperature, over-current, water cut-off and misoperation, and is equipped with simple fault diagnosis function, which can display the fault source in time and has an audible and visual alarm system. There is an emergency stop button on the front of the control panel. There is a cooling system in the control cabinet, which has shockproof function to ensure the long-term stable operation of the equipment.
(2) Double door control cabinet is adopted to separate strong and weak current. The layout of various instruments on the control cabinet panel is reasonable. The display screen can visually display the working state of the furnace, and the automatic and manual modes of the equipment can be switched. The control cabinet is reserved with standby operation buttons, which can be locked at ordinary times; When the industrial computer control system fails, the standby control unit can be started,
7.5.6 safety and self-protection control
It can realize the alarm and interlocking protection of water pressure, overtemperature, overcurrent, overpressure, under air pressure, couple breaking, phase loss of diffusion pump, oil temperature overtemperature of diffusion pump, etc.
Independent overtemperature alarm digital display temperature instrument with accuracy of 0.1 is adopted. With corresponding thermocouple, the furnace can be protected in overtemperature state. In overtemperature state, the visual and audible alarm is also a part of the control system, and there is thermocouple failure protection function.
It has the function of water cut-off safety protection, and is equipped with audible and visual alarm system.
It is equipped with simple fault self diagnosis function, which can display the fault source in time, and has audible and visual alarm and self-protection functions, so that the operation is simple, easy to learn and easy to use, and the operator can quickly be familiar with the use and maintenance of the equipment.
7.6 pneumatic system
It is used for the power supply of each pneumatic valve. It is composed of filter, pressure reducing valve, pressure gauge, electromagnetic directional valve, oil-water separator, cylinder, pressure switch, pneumatic connector, pneumatic pipeline, etc. the pipeline direction is clean and beautiful. It can provide clean compressed air for pneumatic components (such as cylinder, inflation valve, vacuum valve, etc.). It has the function of abnormal air source pressure alarm (electric control function).
7.7 water cooling system
When the equipment works, the furnace door, furnace shell, heat exchanger, motor cover, electrode and vacuum unit need to be cooled by water, and a set of circulating water cooling system including inlet distribution pipe and return pipe is equipped.
(1) Water cooling is a closed water supply and drainage system composed of stainless steel stop valve, vertical water meter, electric contact pressure gauge, electric contact water temperature gauge, pipeline, water flow observation mirror, etc.
(2) The cooling water system has the following functions:
1) It can directly observe and measure the flow of each branch pipe, and has the functions of over temperature, over pressure and water cut-off alarm. The flow speed of cooling water circuit can be adjusted manually by manual valve.
2) The water diversion device is equipped with water inlet and return pipes, valves and electric contact pressure gauges, which form an interlocking protection system with the control part, so as to achieve the purpose of effective operation of the protection equipment.
3) The system is equipped with emergency interface for tap water. In case of sudden abnormal power failure, it can ensure that the water circulation can continue with small flow, which is used to protect the safety of the equipment in case of emergency power failure..
4) The audible and visual alarm can be started when the water pressure is under pressure. When no one releases the under pressure alarm, the equipment will automatically close all parts associated with the under pressure according to the operation sequence.
5) The audible and visual alarm of overpressure can be started when the water pressure is too high. When the water pressure reaches a certain value, the safety valve acts to release the water pressure to protect the equipment from damage.
7.8 automatic walking furnace feeding trolley
The feeding trolley outside the furnace is a vertical operation structure, which adopts automatic mechanical structure. It walks along the fixed track, and the feeding and discharging is accurate and convenient.
Automatic feeding trolley can be designed for multiple furnace types to realize cleaning, quenching, carburizing, tempering and continuous production line.
8.Security measures, alarm and interlock
The equipment shall be manufactured in accordance with the relevant standards and regulations of National "occupational safety and health standards", and shall be equipped with safety devices to protect the operator, the workpiece to be processed and the equipment itself. Install alarm display lights at obvious positions to prevent accidents caused by improper operation.
Reliable safety and alarm devices are equipped for temperature control, cooling water and process.
8.1 heating state
When the temperature in the furnace exceeds the alarm temperature set point, an alarm will be given.
When the cooling water pressure is lower than the alarm pressure set point, the alarm will be given.
When the compressed air pressure is lower than the alarm pressure set point, the alarm will be given.
In case of power failure, all valves in the vacuum system will close automatically.
When the vacuum degree is insufficient during the heating process of the furnace body, an alarm will be given.
When the air pressure in the furnace exceeds the set value, the system can automatically relieve the pressure for protection.
When the gas pressure in the furnace exceeds the overpressure set point, it will give an alarm and automatically close the charging valve.
The electric control cabinet is equipped with an emergency stop button, which can stop working immediately in case of failure.
Note: the alarm time of over temperature, water cut-off or low water pressure exceeds 5 minutes. If there is no intervention, the heating will stop automatically.
8.2 cooling state
If the cooling fan has been started and operated, when the gas pressure in the furnace is lower than the set value of cooling pressure, it will automatically replenish air.
When the gas pressure in the furnace is too high, the safety valve on the furnace body will automatically open and vent.
8.3 safety interlock
Logic interlock between switching actions of electric control system to avoid damage to equipment caused by misoperation.
Working vacuum and heating, water pressure and heating are equipped with interlocking circuits.
Roots pump is equipped with starting pressure interlock.
Relevant safety interlocks shall be set for each vacuum valve system.
Set alarm and safety interlock for phase loss of main power supply.
Set alarm and safety interlock for water shortage of main water inlet.
8.4 safety measures for furnace door
If the gas pressure in the furnace and the outdoor pressure are unbalanced, the furnace door cannot be opened.
If the emergency stop button is pressed, the operator needs to restart manually after the fault is eliminated.
9.Standards of manufacture, inspection
| Item |
Parameters |
Inspection Standard |
| Vacuum degree |
0.1 Pa |
GB/T 16876-1997 |
| Time for vacuum pumping |
15 min |
|
| Pressure leakage rate |
0.50 Pa/h |
GB/T 10066.1 |
| Temperature difference |
±5ºC |
GB10066 |
| Temperature control deviation |
±1ºC |
|
| Gas quenching pressure |
10 Bar |
|
| Indicating error of recorder |
0.5% |
|
| Hardness and brightness after quenching |
As contract requirements |
JB/T 6955 |
| Quality control of heat treatment |
As contract requirements |
JB/T 10175 |
| Hardness inspection |
As contract requirements |
GB/T 230.1
GB/T 4340.1
JB/T 6050 |
| Heating zone dimension |
As contract requirements |
GB/T9452 |
10.Technical documents for users
Factory inspection certificate
Quality Guarantee certificate
Ground Foundation drawing
Layout plan
Electrical control schematic diagram
Vacuum & inflation system diagram
Pneumatic & water-cooling system diagram
Operation and maintenance manual
11.Tools and spares for users
a. 1 set of tools for maintenance
b. Spare Parts:
| Item |
quantity |
| Sealing elements |
1 set |
| Heating elements |
1 set |
| Insulation porcelain |
1 set |
| Temperature meter units |
1 set |
12.Origin of main parts
| Parts |
Origin |
| Computer control system |
Yanhua,Taiwan |
| PLC |
Siemens,German |
| Vacuum gauge and supportings |
Zhenghua,China |
| Platinum thermocouple (s type) |
Dazheng,China |
| Voltage regulator 1x160KVA/3x380 |
Zhangjiagang,China |
| 2X-70 Mechanical pump |
XILIJIA,CHINA |
| ZJP-600 Roots pump |
YANGGUAGN,CHINA |
| Vacuum pneumatic valve GDQ-200 |
DIAMOND,TAIWAN |
| Pneumatic components |
AIRTEC,TAIWAN |
| Electrical components |
SCHNEIDER,FRANCE |
| Vacuum water cooling fan |
JINLONG,CHINA |
| Frequency converter fan |
DERUISI,CHINA |
| High purity graphite element |
ATAIKE,CHINA |
| Insulating element |
HONGYANG,CHINA |
| Vacuum pressure sensor |
DANFOSS,GERMAN |
Company Profile
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