4. Production Process Flow Loading→ Transfer the
cylinder to the loading conveyor of Quenching Furnace by overhead
crane→ Quenching Furnace Door Open→ Convey the cylinder into the
Quenching Furnace rapidly → Heating cylinder inside of Quenching
Furnace(Meanwhile, cylinders moves slowly to prevent the roller
from distortion and increase the uniformity of heating)→ Middle
Door (Heat Insulation) Open → Cylinders transferred rapidly to the
Holding zone of Quenching Furnace(Meanwhile, cylinders moves slowly
to prevent the roller from distortion and increase the uniformity
of holding)→ After process time is completed → Unloading Door Open
and the cylinders are unloaded quickly → Door Close, Cylinders are
transferred to the Side Unloading Conveyor of Quenching Tank→
Transfer cylinders into the Quenching tank for Quenching.
Meanwhile, the transfer car moves up and down, as to uniform the
quenching media and ensure the quenching quality → Lift up
cylinders with Transfer car → Convey cylinders to loading conveyor
of Tempering Furnace → Tempering Furnace Door Open → Transfer into
tempering furnace for heating(working sequence, Takt time, control
mode are all same as quenching furnace)→ Tempering Furnace Door
Open after the process time is reached → Unloading rapidly →
Cylinders are transferred to Unloading conveyor, cooling down and
waiting for unloading → One cycle is completed, Waiting. 5.
Brief Equipment Introduction 5.1 Loading Conveyor It is
mainly designed for loading and rapid convey of steel cylinder,
which consist of supporting bracket, roller, driving device, and
control device. Support Bracket: It is made of formed steel and
steel plate and welded together, which provides a good appearance.
Anchor plate is welded to the bottom of supporting bracket, which
is fixed onto the embedded plate of foundation, as to ensure the
reliability and safety. Roller Conveyor: It is made of 20#
seamless steel tube (φ159×6mm). Positioning device is equipped with
the roller to prevent the offset of steel cylinder and falling down
during moving. Two ends of roller is made of 45# steel and machined
into the shaft shape, and fixed onto the supporting bracket with
the bearing. Locating bolts are equipped with the bearing to
prevent the roller from deviating. Driving Device: It is
driven by speed reducer through sprocket wheels and chains. The
speed reducer is recommended to select MD Series helical gear
redactor, made by Omiter, Shanghai. Control
Device: Driving speed is controlled by Siemens
Frequency Converter that outputs signal to speed reducer, as to
achieve the speed control of roller. Operation
terminal boxes are equipped with both of loading and unloading
conveyor, which consists of push buttons like Start, Emergency
Stop, Reverse, and etc.. The conveyor starts to work after pressed
Start. A pair of photoelectric switches is equipped at
the end of roller conveyor. When cylinders pass through the
conveyor, photoelectric switch sends out the signal to PLC, and PLC
will send the signal to control the speed reducer automatically.
Emergency Stop and Reverse are used under
emergent conditions.
Interlock: All driving system is interlocked with the furnace. It
can't be loaded and unloaded until the furnace door opens in place.
5.2 Quenching Furnace It consists of furnace shell, lining,
furnace door and its lifting device, roller conveyor, roller
driving system, access door, combustion system, exhausting system
and etc.. Furnace Shell: It is made of steel plate and formed steel
and welded together which provides a good appearance (Welds height
is no less than 5mm). Outer shell is made of formed steel which
provides a good strength. Lining: It adopts compound structure. The
lining material is different at bottom furnace, furnace door, side
wall and roof. Bottom Lining: Bottom of furnace shall be cleaned
regularly for removing the oxides, therefore, bottom liner is made
of light-weight refractory bricks and aluminosilicate fiber.
Refractory bricks are on the top surface, as ease to remove oxides.
Aluminosilicate fiber is applied between refractory brick and steel
plate for heat insulation. Liner of Furnace Door: It is made
of heavy weight high aluminum bricks, which is to prevent the
lining from being worn out. Liner of Side Wall and Roof: For energy
saving and reduction, the insulating materials, pre-compressed
aluminosilicate folding blocks (Working temperature is more than
1100ºC), are supplied by Yeso, which will be installed onto the
side wall and roof through the special anchors (1Cr18Ni9).
Insulating material shall be selected based on the various needs
and requirement, such kind of compound structure is less weight,
more reliable, less maintenance, minimized the heat loss. Furnace
Door and Its Lifting System: Quenching furnace has tow temperature
zones, one zone is heating and the other is holding. Middle door is
designed between two zones, which is made of heat resistant cast
iron. Loading and un
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