Vertical type vacuum brazing furnace
Vertical, bottom loading with trolley, Dia 800*H 3000 mm, 8*10-5 Pa, 1300ºC,800 KW
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.
PJ-QH800 vacuum furnace is an internal heated cold wall vacuum heating equipment with high thermal efficiency and good furnace temperature uniformity. At the same time, it can rapidly heat and cool the processed workpieces, effectively shortening the heat treatment cycle of workpieces and improving production efficiency.
The vacuum furnace adopts the first advanced automation and intelligent equipment in China to realize automatic programming and process change at any time according to requirements, thus ensuring automatic heating and cooling under vacuum state. Especially in the furnace, the advantages of several domestic manufacturers are combined, especially in the design of air duct and heat exchanger. The equipment has higher cost performance than many domestic manufacturers
Aplication:
Pjqh-800 single chamber vacuum brazing furnace is used in aerospace / aviation, weapons, automobile, electronics, machinery industry and other fields. Single chamber vertical vacuum heat treatment equipment with 1.7 bar air cooling function is applicable to various vacuum heat treatment processes such as annealing and tempering of high-speed steel and high alloy steel tools and dies, annealing and vacuum brazing of soft magnetic materials and titanium alloys.
Vacuum annealing
Vacuum tempering
Vacuum aging treatment
High temperature brazing
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MAIN PARAMETERS
| ITEMS |
Parameters |
| Basic Parameter |
| Structure |
Vertical, single chamber with 1 door in bottom,bottom loading |
| Model |
PJ-QH800 |
| Hot zone dimension |
φ800×3000mm |
| Loading Capacity |
1000 kg |
| Total height of furnace |
9000 mm |
| Total weigth |
About 35 Ton |
| Temperature Parameter |
| Max design temperature |
1300ºC |
| Working Temperature |
500ºC-1250ºC |
| Temperature control accuracy |
≤1ºC |
| Temperature uniformity |
≤±5ºC (in temperature holding) |
| Temperature control zones |
4 zones(cover, body top, body down, bottom) |
| Temperature raise rate |
≤90 min (raise from 30ºC to 1100ºC in empty furnace) |
| Vacuum Parameter |
| Ultimate Vacuum |
4*10-5PA |
| Work Vacuum |
8.0×10-4Pa |
| Vacuum system |
1 set of Turbomolecular pumps, Roots pumps& Rotary vane pumps |
| Pressure raise rate |
≤0.30Pa/h |
| Partial pressure |
1pa-133pa |
| Pumping speed |
≤30min(8.0×10-3Pa) |
| Electricity Parameter |
| Power Voltage |
Any Standard power voltage |
| Control Power |
220V±5% |
| Total Power in use |
About 800KW |
| Total Heating Power |
700KW |
| Cooling fan power |
75KW |
| Vacuum pump power |
15+7.5+18KW |
| Measurement and view |
| Thermocouples |
3 nos.; for taking temperature measurement by physically touching the thermocouples to brazing jobs at three different points. |
| Glass view window |
1 nos; |
| Extra port |
1 nos.;extra vacuum port DN50 fitted with blank flange. |
Main structure and configuration description
PJ-QH800 single chamber vacuum brazing furnace is composed of furnace body, working chamber, vacuum system, gas cooling system, cooling water system, control system,lifting system,electrical control system and auxiliary equipments.
Furnace body
The furnace body is a vertical structure composed of a vacuum furnace shell and a furnace door. The overall design is 304 stainless steel for the inner wall, carbon steel for the outer wall and cooling water for the middle. The overall design bearing pressure of the furnace shell is 2bar to ensure that the furnace shell will not deform after long-term use.
Furnace shell
The furnace shell is a circular, double-layer water-cooled structure, and cooling water is passed through the interlayer. Both ends are welded with processed flanges. Double layer water-cooled carbon steel structure, both ends are welded with processed flanges.
Furnace cover
1) The furnace cover is of double-layer water-cooled structure with processed flanges.
2) The furnace cover adopts side door, and the furnace door is hinged with the furnace shell, which can be opened flexibly.
3) The furnace cover is locked with a locking ring locking structure.
4) When loading and unloading workpieces, open the furnace door, and the hopper car will directly send the workpieces into the furnace.
5) Special shaped temperature resistant rubber sealing ring is used for the sealing of furnace shell and furnace door to ensure the sealing of positive and negative pressure.
6) There is a quartz glass observation window on the furnace cover.
7) The furnace door opening / closing button is installed on the furnace cover.
8) The furnace cover is lifted and lowered by a reducer, and the automatic rotation mode is adopted
Connection interface
The furnace body provides interfaces for connecting with other systems, such as thermocouple, vacuum system, gas cooling system, furnace temperature uniformity test interface and furnace temperature test components.
Furnace liner
Heating element (high temperature molybdenum lanthanum alloy)
The high-temperature molybdenum lanthanum alloy belt is arranged around the workpiece, and multi-directional radiation ensures uniform heating. The parts made of high-temperature ceramics are fixed in place in the form of plug-in. The arc surface is pressed at the center of the molybdenum belt to offset high-temperature deformation and contraction, so that it can be easily replaced in case of accidental damage, saving maintenance time and reducing cost consumption.
Heat shield (reinforced)
Composite structure composed of high-temperature molybdenum screen and stainless steel screen. It is installed in the support structure of a heating zone, and each layer is supported by an expansion pad, which effectively offsets the expansion and contraction of metal materials under high temperature deformation. The thermal insulation layer structure is distributed as follows:The inner three layers are molybdenum lanthanum alloy, the middle two layers are heat-resistant steel, the outer two layers are stainless steel, and the frame is stainless steel structure. (7 floors in total)
Supports and fasteners
The insulating ceramic separates the heating element and the heat shield from each other, and can adjust the thermal expansion of the heating element and the heat insulation part. The heating element and the support can move relatively slightly, which is easy to disassemble and install.
The furnace liner is fixed with 304 material, which can resist high pressure and high temperature deformation.
Material table support
The high temperature Mo La alloy table provides a stable support for the workpiece load.
Modular design
The heating element and the heat shield are easy to replace and disassemble, and there is no need to take out the furnace liner for maintenance. The furnace liner is of integral structure and can be taken out as a whole during equipment maintenance.
Thermocouple
Thermocouples are arranged in the heating chamber from top to bottom, adopting double core and double branch structure for temperature measurement and alarm. The temperature measuring couple at the center of the workpiece is added, and the wire of the temperature measuring couple is placed inside the workpiece to directly display the temperature at the center of the workpiece, which is visually displayed, and can be linked with the temperature control couple to reduce manual intervention.
Nine point temperature measurement
The frame of the heating chamber is provided with a special opening for the temperature measuring couple, and the armored direct plug-in connection mode is adopted. The temperature measuring module communicates directly with the industrial control computer, and the measurement data is directly displayed in the screen window.
Vacuum system
The vacuum system can achieve the required vacuum degree set according to the heat treatment process requirements and maintain the vacuum state set in the furnace. The fully automatic vacuum system basically includes:
1) High vacuum pump system: composed of mechanical pump, roots pump and turbomolecular pump;
2) Connecting pipes, instruments and valves: the main vacuum valve is installed on the exhaust pipe of the furnace shell with flanges to separate the pump from the furnace shell. Flexible connection of pipes can prevent vibration transmission.
All vacuum valves are interlocked according to the logic relationship during the whole process (from the initial vacuumization to the final inflation). In case of power failure, the valve will automatically close to protect the state in the furnace.
Gas cooling system (internal circulation)
The gas cooling system is installed on the top of the furnace body and adopts internal circulation cooling mode.
The inert gas used for heating and cooling inflation is provided by an air tank. Pipe size and valve selection are consistent with industrial application standards.
Inflator (2bar)
The pressure of cooling gas can be adjusted according to different processes. The pipeline between the high-purity nitrogen gas storage tank and the furnace body is equipped with a pneumatic adjustable controllable flow charging valve, which can realize rapid gas charging and automatic gas replenishment. The air tank is manufactured according to the pressure vessel standard.
Cooling circulation device (large flow reinforced type)
The gas circulation cooling system includes a motor, a cooling fan and a copper shaped heat exchanger device specially used for the vacuum furnace. The heat exchange device is made of round all copper and welded fins, which can improve the heat exchange efficiency, quickly cool the gas and obtain the best cooling efficiency. The motor drives the cooling fan to rapidly blow the cold air flow from the nozzle to the workpiece. The heated gas is cooled by the heat exchange device, and the cooled gas is again blown to the workpiece by the fan at high speed, thus forming a gas circulation circuit.
Electric control system
The system is composed of two parts: a programmable temperature control system composed of voltage regulator, thyristor and microprocessor, and a programmable mechanical action control system composed of PLC and various actuators. It can realize automatic program operation and has manual operation function. This system can realize:
*Industrial computer remote monitoring;
*Manual / automatic control of production process;
*Programmable temperature control;
*Programmable control of mechanical action;
*Chart record of temperature;
*Vacuum degree record;
*Water pressure, overtemperature, overcurrent, overpressure, underpressure, disconnection and other alarms and interlock protection.
1 the integrated industrial control computer is used to control and record the working conditions of the whole equipment:
*Traditional operating system, easy to learn and use. Good graphical human-machine interface; It can dynamically display the process and mechanical movement status in real time.
*It is equipped with 19 inch touch LCD display, large capacity hard disk, 2G memory, and dual core processor for CPU, ensuring that it is the mainstream configuration at this stage.
*Massive storage space and great expansion potential. The operator level identification is divided into four levels, with four levels of password. Each operation authority is protected by password.
*The configuration software adopts the famous brand - Kingview.
*Fully digital monitoring of temperature, vacuum and other data information, and data storage and curve recording can be carried out at the same time.
*Setting of heat treatment process parameters (up to 1000 heating curves can be set according to the needs of different customers);
*It has the database management function and can edit, save, modify and delete the heat treatment parameters. It can store more than 1000 heat treatment processes and support fuzzy query;
*The industrial control computer system is equipped with a USB interface to facilitate the storage and output of data files. It is also equipped with an RS485 interface and provides a communication protocol to provide conditions for the workshop centralized control system.
*The real-time alarm display function can provide real-time recording, audible and visual alarm and interlock protection for the faults (such as water cut-off, overtemperature, overcurrent, overpressure, overload, etc.) occurring in the working process of the equipment;
*The heat treatment process records are stored in the computer hard disk for easy viewing and printing at any time. The hard disk provides dual hard disks;
*After the heat treatment, the historical curve, historical data and alarm information can be printed.
*It can be equipped with A4 color inkjet printer, with multiple recording channels, and can print relevant reports or graphic curves.
2 the 3004 intelligent double loop temperature controller (Euroland, UK) is adopted, with a temperature control accuracy of ± 0.1%, which can store 20 groups of process curves, 25 segments per curve, multiple groups of PID parameters, and has the function of PID parameter self-tuning.
3 Siemens 200 series programmable controller (Siemens, Germany) is used to control the mechanical action, which can realize all automatic control of evacuation, valve opening and other actions.
4 yokogawa-sr10000 - recorder series (6 channels, Chinese display) of Yokogawa Instruments Co., Ltd. is adopted, which can continuously record the temperature \ vacuum \ water inlet temperature curve at different positions in the furnace. The stored data can be transferred to the computer through the U disk, and the data of the selected time period can be printed in the form of reports or graphs. (optional)
5 temperature control thermocouple: double core s couple (Platinum Rhodium 10 platinum) is used in each zone, one core is used for temperature control and the other core is used for recording and alarm; With 9-point temperature measuring device, the thermocouple adopts armored K-type thermocouple.
6 double door control cabinet is adopted, with strong and weak current separated. Various instruments on the control cabinet panel are reasonably arranged. The display screen can visually display the working state of the furnace. The automatic and manual modes of the equipment can be switched on the touch display of the industrial control computer. The control cabinet is reserved with standby operation buttons, which can be locked at ordinary times; When the computer control system fails, the standby control unit can be used to avoid delaying production.
7 it is equipped with simple fault self diagnosis function, which can display the fault source in time, and has sound and light 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.
Furnace body appearance
1) Furnace shell: off white
2) Support: deep blue
3) Electrical control cabinet: gray white
Note: the colors of various pipelines are in accordance with national standards; The appearance color can be adjusted according to customer requirements.
Security measures, alarm and interlock
The equipment is manufactured in accordance with the relevant standards and regulations of China's "occupational safety and health standards", and is equipped with safety devices to protect the operator, the workpiece to be processed and the equipment itself.
An alarm display lamp shall be installed at an obvious position to prevent accidents caused by improper operation.
Heating state
1) When the temperature in the furnace exceeds the alarm temperature set point, an alarm will be given.
2) When the cooling water pressure is lower than the alarm pressure set point, an alarm is given.
3) When the compressed air pressure is lower than the alarm pressure set point, an alarm is given.
4) In case of power failure, all valves in the vacuum system will be closed automatically.
5) 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 no one intervenes, the heating will stop automatically.
Cooling state
1) If the cooling fan has been started, when the gas pressure in the furnace is lower than the set value of the cooling pressure, the air will be replenished automatically.
2) When the gas pressure in the furnace exceeds the overpressure set point, an alarm will be given and the charging valve will be automatically closed.
3) When the gas pressure in the furnace is too high, the safety valve on the furnace body will automatically open and bleed.
Safety measures
- the equipment shall be equipped with normal safety devices with interlocking protection function to avoid equipment failure and production accidents caused by misoperation, but the supply of compressed air and cooling water must be guaranteed.
(2) in case of no power failure, the control system will send out audible and visual alarm signals and automatically record the alarm type and alarm time (if equipped with industrial control computer system).
(3) safety measures during heating
*Safety under vacuum or partial pressure: if the vacuum or partial pressure does not reach the set value, stop heating. The heating program remains in the "hold" state. After the vacuum or partial pressure reaches the set value, the heating program will automatically recover and continue to be executed.
*Safety measures for compressed air: if the pressure of compressed air is lower than 5bar, audible and visual alarm will be given, and heating will be stopped manually or automatically according to the program setting.
*Overpressure protection: the equipment is equipped with a safety valve and a manual air release valve. When the actual inflation pressure of the equipment is greater than the set value, the relevant alarm will be given. If someone finds it in time, the manual air release valve can be opened to reduce the pressure of the equipment. If no one finds it and the audible and visual alarm fails, the safety valve can be opened automatically to protect the equipment from production safety accidents;
*Safety measures for cooling water: if the inlet pressure of cooling water is lower than 1bar (this pressure can be set), audible and visual alarm will be given, and heating will be stopped manually or automatically according to the setting of the program; If the preset inlet temperature of the cooling water exceeds 35 ºC (this temperature can be set), an audible and visual alarm will be given, and the heating will be stopped manually or automatically according to the program setting.
*Overheating protection: when the heating temperature exceeds the set value of safety temperature due to failure, the heating will be stopped.
*Safety measures for sudden power failure: vacuum valve and air circuit valve will be closed automatically. The furnace is still under vacuum or atmosphere protection. When the call is made again, the heat treatment process will continue to be performed manually.
(4) safety measures for furnace body
The automatic locking mechanism of the furnace door (if equipped) is equipped with a safety switch to monitor whether its position is correct; If the gas pressure in the furnace and the outdoor pressure are not balanced, the furnace door cannot be opened.
Technical literature
Initial technical documents
After the order contract of vacuum furnace is signed, our company will provide the following documents to the customer before putting into production (1 for each):
1) Main technical parameters of vacuum furnace;
2) List of main supporting parts of equipment;
3) Equipment layout plan or foundation drawing;
Final technical documents
1) Electrical schematic diagram;
2) Layout plan and foundation drawing.
3) Equipment operation manual;
4) Instructions for main supporting parts;
5) Packing list;
6) Factory certificate of equipment;
Other documents and materials deemed necessary by the demander.
Manufacture time and Business schedule
- Manufacture time: 6 months after we received the pre payment or L/C.
- PSI time: Within 1 Week after we finished the manufacture.
- Delivery time: Within 2 Weeks after PSI (pre shipment inspection) but after the receive of final payment(if payment by T/T).
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:
Cold regulation test items:
Appearance and integrity acceptance of equipment;
Heat regulation test items:
1) Test the limit vacuum degree, pressure rise rate and working vacuum degree after fully drying the furnace;
2) Temperature rise speed, cooling speed and pumping speed detection;
3) Furnace temperature uniformity detection;
4) Working conditions of water and gas;
5) Check the operation steps;
6) Check mutual interlocking and safety alarm;
7) Final acceptance: on the basis of the above acceptance, the heat treatment test of typical parts of 2-3 furnaces shall be carried out as required. After meeting the requirements, the equipment shall be deemed as qualified.
When measuring the limit vacuum degree and pressure rise rate, the furnace body shall be clean, empty and degassed.
Operate 2-3 heats, record the operation information, and conduct the performance acceptance test after the system runs normally. The main acceptance assessment contents and indicators shall be implemented according to the relevant contents of the technical agreement signed by both parties.
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.
Notation: The following conditions are not within the scope of quality assurance:
1) Failure caused by natural disaster or force majeure;
2) Faults caused by illegal operation and improper storage;
3) Failure caused by using the equipment without following the operating instructions;
4) Consumables and quasi consumables (all seals, heating elements and heat-resistant steel parts, etc.);
5) Failure caused by the specification of public facilities provided by the user does not meet the equipment requirements;
6) Loss caused by gasification and melt produced by the treated material;
7) Others are not the responsibility of the company.
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