After a year and a half of dedicated effort, the development of the rotary hearth-pushing furnace linkage normalizing unit has been successfully completed. The system is now in operation at a facility in Jiangsu, where it has been running smoothly and efficiently. All technical specifications meet the design requirements, with precise and reliable automatic control, and the production capacity fully complies with industry standards. The unit has received positive feedback from users, and after six months of operation, nearly 4 tons of automobile gear blanks have been processed, yielding significant economic benefits.
This new heat treatment equipment, designed to suit local conditions and integrate human-machine collaboration, has demonstrated outstanding performance in real-world applications. It represents a major advancement in the field of industrial heat treatment.
**1. Development Benchmark**
The project was developed under budget constraints, with a strong emphasis on ensuring economic returns. The core design principles were as follows:
1) We utilized well-established technologies from rotary hearth furnaces and pusher furnaces, integrating them to reduce technical risks. The focus was on creating a flexible combination that maximizes efficiency and adaptability.
2) To improve working conditions, all handling of heated workpieces is automated using robots. This reduces the physical strain on operators, who no longer need to manually handle hot components, thus improving safety and comfort.
3) The system is controlled by a computer with memory storage capabilities, allowing for single-machine operation, manual control, or full automation. To ensure stability in the challenging heat treatment environment, mechanical travel switches are used instead of more sensitive sensors, providing intuitive and reliable operation.
4) A visual simulation display is included to simplify operation and reduce the skill level required for staff, while also minimizing maintenance needs.
5) The system is designed to support both large-volume, single-variety production and smaller batches of multiple varieties, making it highly versatile and cost-effective.
**2. Unit Introduction**
The NS2002-6001 rotary hearth furnace-pusher furnace linkage group consists of a manipulator, an operation control system, and a hydraulic control system.
**2.1 Pusher Furnace**
Designed to meet the production schedule and customer requirements, the pusher furnace includes process parameters, workpiece size, and furnace capacity. It comprises a pushing mechanism, heating chamber, quick cooling chamber, control system, tray return system, and hydraulic device.
- **Pushing Mechanism**: This component feeds the heat-resistant trays into the heating chamber. It features a fuel tank and push rod with adjustable thrust (1–5 tons) and stroke (700 mm), along with cold and hot positioning devices for deformation compensation.
- **Heating Chamber**: The main part of the electric furnace, featuring three heating zones for heating, insulation, and rapid cooling. It uses heat-resistant steel rails and rollers, and the temperature can be independently controlled according to the process curve.
- **Quick Cooling Chamber**: Essential for isothermal normalizing at 600°C, this chamber allows for rapid cooling with adjustable air volume and wind speed. It automatically regulates temperature based on real-time measurements.
- **Tray Return Device**: Located on the side of the furnace, it uses a step-type transmission for automatic tray return.
- **Hydraulic System**: Composed of a vane pump, motor, and integrated module, it powers all operations and is closely connected to the electric control cabinet.
**2.2 Rotary Hearth Furnace**
This furnace is designed to rotate according to process requirements, with a maximum rated temperature of 950°C. Key components include the furnace shell, bottom, heating elements, and door opening/closing mechanism. The furnace features a split cover for easy maintenance, adjustable rotation speed, and a stable, quiet operation.
**2.3 Inlet and Discharge Manipulators**
These robotic arms enable seamless integration between the rotary hearth and pusher furnace, performing a series of programmed actions. They are built with high-quality heat-resistant materials and designed for durability under high temperatures.
**2.4 Automatic Control System**
The system includes digital displays and multi-point chart recorders for temperature monitoring and recording. It is controlled by a PC, with over 50 travel switches ensuring accurate and smooth operation. The program is fully developed in-house, demonstrating the system’s advanced automation capabilities.
**3. Unit Features**
**3.1 Moderate Automation, Human-Centered Design**
Rather than pursuing full automation, the unit focuses on practical automation that enhances operator comfort and efficiency. Operators handle preparation, inspection, and documentation, while machines manage the heavy lifting. Two workers can process 1,500 kg of gear blanks per shift, showcasing the balance between human input and machine precision.
**3.2 Adapting to National Conditions and Market Needs**
The unit combines pusher and rotary hearth furnaces, both of which are technologically mature and widely accepted in China. It meets diverse process requirements and offers cost-effective solutions compared to imported systems.
**3.3 Flexible Linkage for Multi-Level User Needs**
The system uses a robot for feeding and discharging, enabling both continuous large-scale production and independent single-machine operation. It supports various workpieces and is compact, ideal for small businesses.
**3.4 Cost-Effective Design with PC Utilization**
The control center is an industrial PC, offering simplicity, reliability, and cost-effectiveness. It achieves 90% functional utilization with 10% spare capacity, eliminating the need for high-end controllers.
**3.5 Promoting Green Manufacturing**
By reducing noise, emissions, and energy consumption, the unit improves the working environment and supports sustainable practices. It sets a new standard for eco-friendly heat treatment.
**3.6 Versatile Applications**
The unit is suitable for a wide range of heat treatment processes, including normalizing, annealing, and isothermal aging of gears, shafts, and other steel components.
This innovative system not only meets current industrial demands but also paves the way for future advancements in heat treatment technology.
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Jiangmen Lihua Import & Export Trading Co., Ltd. Jiangmen Lihua Furniture., Ltd. , https://www.jmlihua.com