After a year and a half of dedicated effort, the development of the rotary hearth-pushing furnace linkage normalizing unit has reached a successful conclusion. The system has been officially deployed in a facility located in Jiangsu province, where it is operating smoothly and efficiently. All technical specifications meet the design requirements, with precise and reliable automatic control systems ensuring consistent performance. The production capacity aligns with industry standards, and the unit has received positive feedback from users.
Following six months of continuous operation, nearly 4 tons of automobile gear blanks have been processed through the system, showcasing impressive economic returns. This innovative heat treatment equipment, designed to suit local conditions and integrate human-machine collaboration, has proven its effectiveness in real-world applications.
**Establishment of the Development Benchmark**
The project was developed under strict financial constraints, with a clear focus on ensuring economic viability. The core design principles included:
1. **Technical Maturity**: We leveraged well-established rotary hearth and pusher furnace technologies, combining them to minimize risks and enhance flexibility.
2. **Human-Centric Design**: To improve working conditions, all movement of heated workpieces is fully automated using robots, reducing physical labor and exposure to heat.
3. **Computer Control**: The system features a computerized control system with memory storage capabilities, supporting both manual and automated operations. Despite environmental challenges like dust and temperature fluctuations, we used travel switches for stability and ease of maintenance.
4. **Visual Simulation**: A visual display interface was incorporated to simplify operation and reduce the need for highly skilled personnel.
5. **Multi-Purpose Use**: The unit is designed to handle both large-volume single-product runs and small-batch multi-variety production, maximizing its versatility.
**Unit Introduction: NS2002-6001 Rotary Hearth - Pusher Furnace Linkage Group**
The system comprises a manipulator, an operation control system, and a hydraulic control system. The pusher furnace is tailored to meet specific process requirements, including workpiece size, furnace capacity, and heating parameters. Key components include:
- **Pushing Mechanism**: Equipped with a fuel tank and push rod, capable of adjustable thrust (1–5 t) and stroke (700 mm), with cold/hot positioning devices for deformation compensation.
- **Heating Chamber**: Constructed with steel, refractory, and insulation materials, featuring three heating zones for precise temperature control. It includes rails and rollers made of heat-resistant steel.
- **Quick Cooling Chamber**: Designed for isothermal cooling at 600°C, with adjustable airflow and automatic temperature regulation based on real-time data.
- **Tray Return System**: Utilizes a step-type transmission for automatic tray return, supported by a hydraulic station that powers all operational sequences.
- **Rotary Hearth Furnace**: Capable of rotating up to 950°C, with a modular design for easy maintenance and efficient heat distribution via radiant tubes.
**Automatic Control System**
The unit features a digital temperature display and multi-point recorder, enabling precise temperature settings and monitoring. The PC-based automation system manages over 48 cycles of robotic feeding and discharging, ensuring seamless operation. With more than 50 travel switches, the system supports accurate and safe movement of the pusher furnace and related components.
**Unit Features**
1. **Moderate Automation**: Focused on improving operator comfort rather than full automation, the system enhances productivity while maintaining a balanced human-machine interaction.
2. **Cost-Effective Design**: By avoiding high-end sensors and using standard travel switches, the system remains affordable and user-friendly, significantly reducing costs compared to imported alternatives.
3. **Flexible Linkage**: The robotic manipulator enables smooth integration between the rotary hearth and pusher furnace, adapting to varying production needs.
4. **Low Cost and High Efficiency**: Utilizing a common industrial PC for control ensures cost-effectiveness and reliability, with 90% of functions fully utilized.
5. **Green Manufacturing**: The system operates quietly, minimizes heat loss, and reduces environmental impact, promoting sustainable production practices.
6. **Versatile Applications**: Suitable for various heat treatment processes such as normalizing, annealing, and isothermal aging of steel components like gears, shafts, and crankshafts.
This project marks a significant achievement in the field of heat treatment technology, demonstrating how innovation can be both practical and economically viable.
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Jiangmen Lihua Import & Export Trading Co., Ltd. Jiangmen Lihua Furniture., Ltd. , https://www.jmlihua.com