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Furnance size: 800* 10000mm
Total loading power: 780kw; normal power: 420kw;
power supply 3phase, 380v, 50Hz;
Total length: about 47m;
Total weight:60000kg;
1 Working temperature:
Precleaning machine: 40～60℃; quenching furnace:820～950℃;
quenching tank.60～80℃; post-cleaning machine: 40～60℃;
tempering furnace: 200～450℃;
2 productivity
Quenching: 500-1000kg/h ( varying with the workpiece size, weight, stacking method, and other related conditions)
3 furnace atmosphere:
Quenching furnace: methanol+propane+ammonia;
Tempering furnace: air
4 magnetic belt charging machine
Mesh belt width: 900mm
5 Precleaning machine
Mesh belt width : 800mm
Effective length: 2400mm
Tank volume: 2m3
6 Vibration distribution machine
Exit width: 700mm
7 Mesh belt type quenching furnace
Mesh belt width: 800 mm
Inlet length: 2000 mm
Preheating belt length: 1500mm
Working area length: 10000mm
Effective height: 100mm
8 quenching oil tank
Mesh belt width : 1200mm
Oil tank depth: 2000mm
Oil tank width: 1800mm
Oil tank length: 4200mm
Tank volume: 14 m3
9 Oil removing stand
Mesh belt width : 1100mm
10 Post-cleaning machine
Mesh belt width : 1100mm
Effective length: 2400mm
Tank volume: 2m3
11 mesh belt tempering furnace
Effective height: 100mm
Mesh belt width : 1100mm
Heating area length: 10000mm
1.Buyer Requirement
1.1 product: steel nails, self-tapping screw;
1.2 process: carburizing, bright quenching and tempering;
1.3 productivity: quenching: 500-1000kg/h;
3. Equipment General Introduction and Main Features
1 General Introduction
1.1 The heat treatment line combines the advanced technologies
from Taiwan. Its key parts are imported from overseas.
1.2 The production line is comprised of magnetic belt charging machine,
pre-cleaning machine, support roller quenching furnace, quenching tank,
oil removing stand, post-cleaning machine, support-roller mesh belt
tempering furnace, and electrical control system.
Features:
2.1 To meet the production needs of fastening parts, the furnace employs
Taiwan technology, and improves its energy-saving effect in the area of
refractory lining.
2.2 The production line employs low-voltage heating through the transformer
to prolong the service life of the heating tubes.
2.3 The mesh belt is supported by the support rollers with synchronized movement
so that the mesh belt bears a minimum tension.
2.4 The rollers are supported by special high-pressure sealed bearing.
2.5 The mesh belt is designed with abnormal transportation alarm device to
assure the stable movement of the mesh belt.
2.6 The drip-in atmosphere is gasified by a gasifier and then sent into the furnace.
The atmosphere is monitored and controlled continuously by an oxygen probe.
2.7 The hot mesh belt returns back to the entrance of the furnace and preheats
the cold partss, which saves energy greatly.
6. Production Line Power and Energy Consumption
6.1 power
Heating power: 380V±10%, 3 phase, AC, 50HZ;
Measuring and control system: 220V±10%, 50HZ
Heating system:about 745kW
Driving system power and other consumption spots: about 40kW
Power supply of the whole line: about 785W
Power consumption at normal working: about 420kW
6.2 atmosphere inlet pipe parameters
Methanol inlet pipe: 4-6 L/h ; ≥0.04 Mpa;
Propane inlet pipe: automatic control with supply ≤500L/h;
supply pressure ≥0.04Mpa;
Ammonia inlet pipe: 3m3/h;
6.3 cooling water
Water quality: according to state standard low-calcium
industrial circulating water;
Suspended substance: max 10mg /L;
Filter mesh belt hole size: max 0.3mm;
Inlet temperature: (max) 30℃(in summer)
Inlet temperature: (min)5℃ (in winter)
Temperature difference: 10℃
Inlet pressure: 0.2 Mpa
Max water consumption: about 100m3/h (circulating use)
6.4 Supplementary Equipment ( supplied by the buyer)
The cooled water tank and cooling tower are usually mounted
outside the workshop
but near the production line. The cooling power capacity should
be ≥100m3/h.
7. Technical Specification Per Unit
Magnetic Belt Charging Machine
The charging machine is comprised of tip frame, vibration silo,
magnetic belt conveyance system, and driving system. The
machine frame is made from sectional steel and steel plates.
1 Chain and sprocket wheel: P=25.4mm, 1 set;
2 reducing gear, 0.55kw (VF speed regulation), 1 set
3 magnetic belt: 900*3450*1/2mm (SUS304) 1 piece
4 Strong force magnetic steel: 28*26*8 1 group;
5 Vibration motor: 150W, 1 set;
6 hydraulic station: 16Mpa/cm2 2.2kw, 1 set;
7 hydraulic oil cylinder: ￠80*800mm 1 set;
Mesh Belt Type Pre-cleaning Machine
The pre-cleaning machine is of the immersion type. It has 3 working
positions which are rinsing, soap water jetting, and strong-air drying.
The charging machine is equipped with the strong force nozzle. And it
is flanked by one water oil separation tank and one oil collection tank.
The oil collected could be used.
tank body
The cleaning tank body is fabricated from steel plates and sectional
steel which are welded together.
2 mesh belt driving device
Mesh belt: 800*7200*1.5/2.5mm 1 piece;
Chain and sprocket wheel : P=25.4mm, 1 set;
Reducing gear: 0.55kW, 1 set;
3 cleaning tank volume: 2000L;
4 cleaning jetting pump: 2.2kW 1 set;
Copper nozzle, several;
5 heating device: 380V/4kW, 6 pieces, 24KW in total;
6 oil and water separation tank
Oil and water separator, 1 set;
Gear motor, 0.37kW 1 set;
7 drying fan at the exit, air conditioning fan, 1 set;
8 temperature controller, RKC, 1 set;
Thermal resistor, PT100, 1 piece;
9 Driving detection device, Omron, 1 set;
10 liquid valve d=15 1 piece;
11 Overloading protector, 1 set;
Vibration Distribution Machine
1 vibration silo 1piece;
2 vibration motor 150W, 2 sets;
Mesh Belt Quenching Furnace
The quenching furnace is the key part of the production line.
It is comprised of furnace shell, front machine stand, heat
preservation material, heating device, temperature control device,
and atmosphere supply device.
1 Main parameters:
Mesh belt width :800mm
Working area length: 10000mm
Entrance length: 2000mm
Preheating area length: 1500mm
Temperature control: 6-zone PID control;
Rated power: 420KW
Furnace temperature uniformity:≤±5℃ temperature uniformity for the
same section:≤±3℃; furnace outer wall temperature rise: ≤50℃
2 mesh belt driving device
2.1 The parts are conveyed through the mesh belt.
2.2 The mesh belt is supported by the support rollers with synchronized
movement. The mesh belt is of the front-driven type, and thus bears a
minimal tensile force at high temperature.
2.3 mesh belt driving speed:50～220mm/min, inverter control;
2.4 mesh belt: 800*26000*2/3mm; 1 piece;
2.5 support rollers
Preheating upper rollers, ￠50 SUS304 5 pieces;
Preheating lower rollers, ￠87mm SUS304 3 pieces;
Upper rollers, ￠50mm SUS310 35 pieces
Lower rollers, ￠87mm SUS310 12 pieces
Rear driving roller, ￠203mm SUS310 1 piece
Bearing UCFL207 110 sets;
2.6 chain and sprocket wheel, P=19.05mm, 1 set
2.7 reducer, 0.75kW 1 set;
2.8 inverter, Mitsubishi, 1 set;
2.9 mesh belt driving detection device, Omron, 1 set;
3 heat preservation material
3.1 The roof wall is lined with 1400 high temperature silicate aluminum
fiber and 1260 silicate aluminum cera blanket, which are fixed by ￠8mm
rods and press plate made of SUS310S.
3.2 The furnace side walls are lined with Isolite anti-carburizing bricks, heat
preservation bricks and heat preservation boards. The lining thickness is 395mm.
3.3 The refractory adhesive is P-150 (Japan brand). It has the characteristics
of stronger bonding effect at higher temperature. It resists a max temperature
of 1600 degree celcius.
4 heating device: electrical heat radiation tubes.
4.1 The electrical heating tubes are installed in the upper and lower wall of the
hearth. The heating system works with low voltage power supply, and the
furnace doesn’t need to be stopped when replacing the heating tubes.
4.2 electrical heat radiation tubes, 66 sets;
a) outer pipe: ￠122*1425*4mm (SUS310S), 66 pieces;
b) heating tube core: OCr21Al6Nb, 66 sets;
c) insulation parts (corundum): 66 sets;
4.3 thermal couple WRN430 K type, 6 pieces;
4.4 Each zone is set with an independent transformer. The heat radiation tube
is in parallel connection, and doesn’t interfere with each other. The heat
radiation tubes are easily maintained.
Transformer, 380V/56V, 6 sets;
Mixing fan (NSK bearing with water cooling system), 4 sets;
vanes (shaft and vanes), 4 pieces;
bearing, NSK, 8 sets;
motor, 1.5kw, 4 sets;
6 exhaust fume device ( removing and burning the fume of the furnace
and the oil tank)
Air pump, 250W, 1 set
7 water tank at the furnace mouth with inside SUS304 layer, 1 set;
8 furnace door
a) movable furnace door at the furnace mouth, 1 set;
b) soft curtain door inside the furnace, 4 groups;
9 dust removal hole, 12 pieces;
The dust holes are set at the lower part of the two side walls of the preheating
and the heating section. The dust hole is blocked with a plug made of the
heat preservation fiber and cover plate. The plug is fixed by the lever mechanism,
and is easy to be removed.
10 The furnace door is also equipped with 1 fire curtain to heat the cleaning
liquid in the cleaning tank.
11 atmosphere supply device
atmosphere supply: drip-in type: methanol+propane+ammonia;
11.1 Atmosphere control:
Oxygen probe, marathon, USA, 2 pieces;
Carbon potential controller, Eurotherm, 2 sets;
Proportional valve, Burket, Germany, 5 sets;
Methanol flow meter, 5 sets;
Propane flow meter, 4 sets;
Ammonia flow meter, 4 sets;
Propane flow meter, 2 sets;
Reference air flow meter, 4 sets
Air pump, 35W, 2 sets
