The development direction of the mesh belt furnace

Net belt furnace development direction:
Mesh furnace production line using non-polluting DX gas tempering black technology, pollution-free use of heat back to heat black technology to replace the traditional pollution of the black process. Net belt furnace heat pollution is zero.
Mesh Furnace Details:
After more than half a century of development, the first generation of mesh belt furnace heating from the oxidative atmosphere gradually developed to the second generation of protective atmosphere, less non-oxidative heating, but also to the third generation of controlled atmosphere heating, the fourth generation of computer management, In the twenty-first century today, the mesh belt furnace is how to develop the characteristics of the mesh belt furnace?
Today's heat treatment mesh belt furnace development and other products from the same market demand, the development of the results from the technical progress. China's reform and opening up policy is greatly promoting and accelerating the heat treatment industry development process.
The 21st century mesh belt furnace technology will have a distinctive characteristics of the times, with four characteristics: intelligent heat treatment, high-quality heat treatment, low-cost heat treatment, clean heat treatment.
1.1 intelligent heat treatment
Research and development personnel using the latest CAD program and heat treatment database, computer simulation technology and control technology, the use of highly flexible, intelligent integrated control and management system in the mesh belt furnace and its production line.
The future mesh belt furnace operator only need to be processed the number of parts, drawings into the computer, the entire set of equipment will handle their own high-quality products.
At present, the whole system real-time multi-project operation control has been realized. Such as control the thickness of the charge, net belt speed, temperature, carbon potential and so on. Full screen monitoring and control of batch feed movement. Can complete the process control, can store 9999 process. (Part number, material, temperature, carbon potential, etc.) detected in the operating condition of the equipment to the computer for processing and storage of records. Can be read and printed at any time. Can store a record for ten years. Password hierarchical control, completely layered. Containing the new furnace heating process, shutdown heating program can be effective in the implementation of the heating process.
1.2 High quality heat treatment
The mass dispersion rate is zero and the heat treatment distortion is zero. Quality control measures:
Feeding control system: weight, quantity, uniformity controllable. To achieve tipping bucket, sucker, tape, ladder, vibration material system is widely used. Feeding rhythm automatic control, frequency control. Parts are automatically aligned. Feeding thickness to achieve real-time monitoring. From the source for the heat treatment process to ensure the accuracy of the implementation.
Equipment temperature control: furnace temperature stability ± 1 ℃, furnace temperature uniformity ± 10 ℃, cold treatment temperature uniformity ± 5 ℃, switch-type temperature control will be eliminated.
Furnace atmosphere control: uniformity of the furnace atmosphere 0.05% oxygen probe, in addition to carbon air pump, carbon potential control instrument, furnace gas regulator with a reliable fit in the net belt furnace. Suitable for nitrogen atmosphere. Methanol acetone (toluene) atmosphere, heat-absorbing atmosphere, exothermic atmosphere. Oxygen probe and infrared instrument The development of multiple carbon potential control technology and other new carbon potential control technology, not only can improve the stability and stability of carbon potential control, will also be able to better adapt to a variety of gas source preparation atmosphere The The control of carburizing and carbonitriding seepage layer is further optimized by carbon potential control technology. Continuous mesh belt furnace water quenching to eliminate the appearance of water vapor stabilized the furnace atmosphere to ensure the stability of the carbon potential control. Methanol gasification, the new development of pyrolysis technology and the furnace mixing fan commonly used, the furnace uniformity of the atmosphere has been further improved. The furnace shell seal welding method not only saves energy but also benefits the long-term stability of the furnace atmosphere.
Quenching tank control: to ensure uniformity of the workpiece hardness and reduce the deformation of the parts from the previous simple to reduce the cooling rate to the development of cooling to improve the uniformity of the quenching tank to add adjustable speed strong stirrer, attention to quenching tank flow field, emphasizing quenching Groove temperature uniformity. Quenching tank temperature controllable. Computer cooling media performance detector is also accepted by many users.
Heat treatment distortion control; use of quenching furnace hot area in addition to stress. The use of fully enclosed with heat controllable classification of quenching oil tank. Quenching medium temperature uniformity 5 ℃. Design of Anti - bump and Bump of Quenching and Hoisting Machine. In order to reduce the amount of retained austenite in the bearing parts, to control the micro-deformation of the bearing after processing, reheating in the reel furnace production line and then increase the cold treatment device will be universal.
1.3 Low-cost heat treatment
Twenty-first century as China's accession to WT0 China's enterprises will be in the international market competition in the environment, the market will be more urgent need for cheap heat treatment equipment. While the cheap heat treatment equipment will be low-cost heat treatment equipment rather than low-cost heat treatment equipment. The cost of heat treatment equipment consists of five parts: equipment acquisition costs, equipment operating costs, equipment maintenance costs, equipment 4T costs, heat treatment failure fee.
Usually equipment procurement costs only 5-10% of the total cost of equipment. For this equipment manufacturers will not strive to provide low-cost heat treatment equipment, but strive to provide low-cost heat treatment equipment.
Therefore, according to RMs (reliability reliability, maintainability maintenance, support support) engineering theory design and manufacture of mesh belt furnace is popular.
Furnace selection: design first from the selection of the right to choose a muffle or no muffle furnace type.
Heat-resistant steel material selection: high-quality Fe-Cr-Ni, Fe-Ni-Cr, Ni-based alloy material, according to the furnace operating temperature range, heat treatment process for a reasonable selection. So that the actual life expectancy and performance and price ratio tends to be more rationalized. Mover life up to 2 - 5 years, mesh belt 2 - 4 years, roller 5 1O years, radiant tube 2 - 4 years, fan 5 - 10 years.
Instrumentation selection: the widespread use of high reliability PLC programmable controller, SRC heating module, adaptive digital temperature control table, carbon control instrument, in the entire equipment life cycle can be achieved trouble-free operation.
Sensing element selection: the atmosphere control oxygen probe life of 1 year, carbon potential control accuracy ± 0.05%, thermocouple life of more than 5 years, the control accuracy of ± 0.05%
Refractory material selection: 0.48 ultra-lightweight anti-carburizing brick, ultra-light insulation board, fire-resistant cotton, life of 5 years.
Common defect prevention device: Prevents parts from knocking bumps; Prevents parts from jumping out of scatter; Prevents parts from jumping badly
Dynamic mechanism of the torque limiter; prevention of parts sticky spray brush device: to prevent the adhesion of parts to add trench;
The liquid is difficult to drain the mountain type, the drum type drying device. Increase the long back to the furnace, to ensure high hardness uniformity.
(2) maintainability: automatic point of failure; failure after the fault point before the automatic shutdown: sound and light automatic alarm 3 equipped with special maintenance tools.
(3) security: dedication to customer service, everywhere for the sake of the user is not an empty talk, more and more manufacturers openly promise to receive the buyer for help phone, promptly assist the buyer to solve the problem: the phone can not solve the problem immediately Send someone to go. The seller sets up the buyer's spare parts library. The seller establishes the reporting system for the spare parts required by the buyer. With the development of emerging network technology to make remote control a reality, the cooperation between suppliers and users will be more understanding, new technology, new technology applications will lead to further decline in costs.
(4) energy conservation: heat treatment "Tenth Five-Year Plan" requirements, the major industrial cities in the city heat treatment plant average power consumption down to 500KWh / t below. The energy consumption of the ribbon furnace will be increased to 360-420 KWh / t (including quenching and tempering).
Widely used heat exchanger technology, waste heat utilization technology, furnace shell airtight welding technology, reducing the furnace surface area (such as cylindrical) energy-saving technology. Using 0.48 ultra-lightweight anti-carburizing brick, ultra-light insulation brick, ultra-light insulation board, refractory cotton furnace technology to furnace wall temperature rise 6 ℃. The use of tempering furnace rapid cooling technology. The use of high pressure air pump oil saving technology. The use of straight air atmosphere with propane can save 80% of the atmosphere. With the realization of the domestic West-East Gas Pipeline project, the direct use of primary energy with the mesh belt furnace will be expanded to use, will bring significant overall energy saving effect. Equipment, energy-saving technology to promote the use of heat treatment process cycle shortened, such as carbon steel zero heat treatment: thin layer carburizing (carbonitriding) direct quenching omitted tempering: double oxygen probe two carbon potential control to shorten carburizing, carbon and nitrogen Co-permeation time and other processes will expand the application.
1.4 Clean heat treatment
In 1992, the World Summit on Environment and Development adopted the "Gamba Agenda" to promote the development of cleaner production. In 1995, China formally listed clean production as a key technology for the development and promotion of the "Decision on Accelerating Scientific Progress". To further promote and develop a variety of clean heat treatment technology and cleaning, cleaning technology 04 '15' during a variety of waste water, waste gas, waste emissions must meet the relevant national standards, 2015 and strive to achieve heat treatment production of environmental pollution approaching zero In the first century, the net belt furnace in the production process to reduce the environmental impact to zero.More use of water quenching medium to gradually replace the quenching oil. Quenching oil to achieve on-line closed-loop control, the use of advanced oil and water separation technology, oil purification technology Oil and water separator separation effect can be less than lOPPM. Centrifugal separation oil purifier, can remove oil 1Lt impurities.) Fume pollution electrostatic recovery technology recovery rate of up to 0.999. Using long hardened mesh belt hot zone length of the implementation of clean Combustion degreasing method.
Mesh furnace production line using non-polluting DX gas tempering black technology, pollution-free use of heat back to heat black technology to replace the traditional pollution of the black process. Net belt furnace heat pollution is zero