1. Overview
This set of equipment has three functions: normalizing, normalizing + tempering, quenching + tempering. Meet the outer diameter of the steel pipe: φ133 ~ φ325mm. The total power is 2500Kw and the frequency is 500Hz.
Inlet water temperature: 0 ° ~ 35 °, water temperature < 55 °
Water pressure 0.2～0.3MPa, air pressure>0.4Mpa
Second, the main components and functions of the equipment
Loading rack
The loading gantry is a stack of steel pipes to be heated. The gantry is welded with a thick 16mm steel plate and 20 hot-rolled I-beams. The width of the table is 200mm, and the table top has a slope of 2.4°. 8 φ325 steel pipes can be placed, and the gantry and column can be placed. Bolted. During work, the crane can hang the whole bundle on the gantry, the bundle device feeds, and the bundle device is driven by the cylinder. After the bundle is bundled, the heated steel pipe will be automatically rolled one by one to the gantry to separate At the material, the separating mechanism sends a piece of material to the end of the loading gantry as needed under the control of the beat. The end is provided with a material positioning seat, which blocks the material and is positioned in the V-shaped groove.
2. Feed translation mechanism
The feed translation mechanism is hydraulically driven. There are 6 sets of feeding mechanism and 6 sets of metallurgical cylinders with cylinder diameter φ50 and stroke of 300mm. In order to ensure synchronization, six sets of hydraulic cylinders are equipped with hydraulic motors. The translation cylinder has 2 sets of cylinder diameter φ80 and a stroke of 750mm. The translation is in place, which is exactly the center of the double roller. Each set of double roller supporting mechanism has 4 wheel sets, and the wheel group supports two 11# light rails, which are accurate, labor-saving, practical and reliable.
3. Double roller drive system
The double-claw transmission device can adjust the angle of the double-barrel to achieve the speed of the steel tube rotation and ensure the speed of advancement. The double-bar linkage transmission adopts a reducer and a frequency converter to ensure the forward speed requirements of steel pipes of different diameters. There are 38 sets of double rollers, 12 sets of feeding ends, 14 sets of middle sections, and 12 sets of discharge ends. The distance between the rollers is 1200mm, the center distance between the two wheels is 460mm, the diameter of the roller is 450mm, and the steel pipes of φ133～φ325 are taken into consideration. One set of rollers is the power wheel, and the other set of rollers is used as the support passive wheel. Considering that the heating furnace has a certain installation. In position, the power wheels are designed with a set of 1:1 sprocket chain drives designed to move the center of the drive connection outward by 350 mm. All the heating zone and the discharge zone of the feeding rod are provided with water cooling device, and the support of the roller is supported by bearings. In order to ensure the uniform and balanced transmission speed of the workpiece before and after, the power uses 38 frequency conversion motors. The speed of the motor is controlled by the inverter. The speed range of the rod is 10~35 rpm, the forward speed is 650~2500mm/min, and the speed range of the inverter is 15~60Hz. The rod is placed at an angle of 5° to the center, the angle can be adjusted to a maximum of 11°, and the minimum can be adjusted to 2°. The adjustment of the angle of the rod is controlled by the motor to drive the turbine vortex in three areas.
The whole double roller linkage is installed on the inclined table of 0.5% from the feeding end to the discharging end, so that the residual water inside the steel pipe can be smoothly discharged after quenching.
By controlling the speed of the feeding rod, the heating rod and the discharging rod, the head and tail of the steel pipe are connected, and the heating furnace is fed in and out until all the tubes of one steel tube leave all the heating furnace body, and The steel pipe that is connected to the head and tail before the upper bed is automatically separated.
4. Heating furnace cooling system
The furnace body was cooled by a FL-1500BP type feng shui cooler from Wuxi Ark. The FL-500 feng shui cooler cools the newly added 1500Kw (two 750Kw) power supplies (the cooling water pipe is stainless steel):
FL-1500BP type feng shui cooler (cooling furnace body) parameters:
Cooling capacity: 451500kcal/h; Working pressure: 0.35Mpa
Working flow: 50m3/h; Inlet and outlet pipe diameter: DN125
Fan rated power: 4.4Kw; pump rated power: 15Kw
FL-500 type feng shui cooler (cooling power supply) parameters:
Cooling capacity: 151500kcal / h; Working pressure: 0.25Mpa
Working flow: 20m3/h; inlet and outlet pipe diameter: DN80
Fan rated power: 1.5Kw; pump rated power: 4.0Kw
5. Quenching liquid cooling system
The furnace body is cooled by the FL-3000BPT type feng shui cooler of Wuxi Ark:
FL-3000BPT type Fengshui cooler (cooling furnace body) parameters:
Cooling capacity: 903000kcal/h; Working pressure: 0.5Mpa
Working flow: 200m3/h; inlet and outlet pipe diameter: DN150
Fan rated power: 9.0Kw; pump rated power: 30Kw × 2
6. Discharge lifting and lowering mechanism
The discharge lifting and lowering mechanism adopts a lever type to keep the hydraulic cylinder away from the hot zone. In order to ensure the flatness of the heating steel pipe, the discharge lifting and lowering device has a total of 11 groups of feeding mechanisms, and is combined into one. The 11-group feeding mechanism can simultaneously lift and lower the material to ensure the synchronization of the heating of the steel pipe. The lifting adopts 2 sets of metallurgical cylinders φ160×360, and the translation cylinder adopts 2 sets of φ80×1200. The travel control is equipped with a proximity switch and can be adjusted. The hydraulic cylinder is equipped with a heat shield.
7. Two-way cooling bed
a. The cooling bed adopts two sets of sprocket chain conveying mechanisms, one set is a drag pulling device and the other set is a drag rotating device.
b. The chain drags the rotating device, the overall plane height of the chain is slightly higher than the height of the chain of the drag pulling device, and the chain drag rotating device moves in a uniform manner with the steel tube rotating. Thereby preventing the deformation of the steel pipe at a certain point without rotation. The motor power is 15Kw, and the temperature after the lower cooling bed is ≤150°C.
c. Drag and pull the device chain to adopt the self-made chain. Each conveyor chain has 20 sets of scraper positioning frame. The movement mode is step-type dragging method. The ratchet mechanism is adopted. The chain and chain center distance is 1200mm. There are 11 pieces, and the drag zipper device does not carry the weight of the steel pipe.
d. Drag the rotating device for a long time and contact with the heated steel pipe, the drive chain will heat up, and the chain will have bad factors for a long time. To eliminate this hidden danger, the pool is built in the center of the drag rotating device, so drag and rotate The chain of the device is cooled while moving.
8. Collecting material rack
The gantry is welded by profile steel. The table top is welded with 16mm thick steel plate and 20 hot-rolled I-beam. The width of the table is 200mm. The table top has a slope of 2.4°. Seven φ325 steel pipes can be placed. The gantry and the column are bolted. The spacing between the gantry is 1200mm, and the end of the gantry is provided with a steel tube limit arm.
An infrared thermometer is arranged at the end of the collecting gantry to measure the temperature after the cooling bed under the steel pipe, and the maximum value of the measured data is sent to the upper computer.
9. Heating furnace adjustment bracket
Electric adjustment, the guide sleeve lifts. Two sets of screw jacks are driven by the gear reducer for height adjustment, and the lifting is stable and reliable.
10. Stop mechanism
When the steel pipe is quenched, normalized, tempered, and quickly reaches the end, it is blocked by the blocking mechanism here. When the proximity switch receives the signal, the discharge lifting and lowering mechanism works, and the chain drag rotating device stops working. . When the lifting and lowering mechanism sends the material to the cold bed and smoothly puts it down, the chain drags the rotating device motor and restarts the work.
11. Hydraulic station
The working pressure is 16Mpa and the volume is 500ml.
Main configuration: double electric double pump, electric control valve, pressure regulating valve, oil level display, oil temperature gauge, oil pressure gauge, oil-water radiator. The hydraulic pipes are made of stainless steel pipes, and the hydraulic oil tanks are welded by stainless steel plates.
11. Quenching liquid spray system
The two-pole gas mist spray system, the two-pole water spray system and the 壹-stage pneumatic spray drying system are used to form an integral spray system. All adjustments are done automatically by the industrial computer and the electric proportional control valve.
12. Quenching liquid collection system
This is done by using an online collection tank with a corresponding quenching fluid collection tank. A filter collection net that facilitates the cleaning of impurities is installed in the collection tank.
13. Anti-chuck system system
A speed measuring device is added between the two rollers at the feeding end to detect whether the tube is stuck (the tube does not move), and the alarm signal is issued once the tube is issued. This device is the same signal as the feed detection switch signal.
13. Heating furnace section
a. Retain the original 1000Kw heating furnace according to the specific conditions of the existing equipment;
b. The added 750Kw (1) heating furnace is placed in front of the original 1000Kw heating furnace, and the original equipment constitutes a normalizing and quenching production line;
c. The added 750Kw (1) heating furnace is mainly heated before the Curie point and heated to 500 ° C, so that the heating capacity of the equipment can be fully utilized, and the heating efficiency is very high;
d. The original 1000Kw heating furnace will undertake heating from 500 °C to 930 °C, and this part will not be changed;
e. The added 750Kw (2) heating furnace mainly undertakes tempering and normalizing treatment of steel pipes;
f. At the station of the quenching liquid collection system, a set of 750Kw normalizing furnace (including compensation capacitor) is also designed. When using this furnace, the intermediate frequency power supply uses the newly added No. 2 power supply (also used for tempering 750Kw power supply), and is switched by changing the furnace switch.
g. The first set of heating furnace body is 750Kw (1), and two heating furnace bodies are arranged between the three rods. The length of the furnace body is 700mm.
h. The normalizing and tempering heating furnaces are divided into three groups according to the workpiece size, and each group is divided into two groups according to the size of the steel pipe: φ133~φ196, φ197~φ260, φ261~φ325. The sensor is 700mm long and two sections are connected in series. The lining is knotted, its fire resistance temperature can reach 1760 °C, and the waterway adopts quick-change joint. In order to adapt to different specifications of the heating steel pipe, the heating furnace is designed with a fixed bracket that can be adjusted up and down, and the screw jack is used to drive the screw jack to adjust, so that the center lines of the heating furnaces of different specifications are at the same height.
i. At the exit end of the normalizing and quenching production line, a set of quenching and spraying devices is arranged to quench the steel pipe, and the steel pipe after the quenching process is completed and enters the tempering production line along the conveying rod.
j. The upper and lower adjustments of the heating furnace and the quenching liquid spray system are all electrically regulated.
14. Voltage stability system
The method of detecting the grid voltage is used to ensure the stability of the heating temperature by automatically adjusting the output power of the intermediate frequency power supply when the grid voltage changes. In addition, when the intermediate frequency power supply changes ±10% of the grid voltage, the intermediate frequency voltage changes only It is 1%.
Third, the operation instructions of the equipment
1. Manually hoisting the material from the crane to the storage rack (when the fork of the baling device is in the vertical position). Manually connect the two-position five-way solenoid valve, the piston rod of the cylinder shrinks, and the fork rod rotates. When it is in position, the bundle is opened, and the heated steel pipe will automatically roll to the feeding mechanism of the separation mechanism. Once there is no material, no The material detection switch sends a signal. Under the control of the control system, the separating mechanism sends the materials one by one according to the beat, and rolls to the end to position. The feed detection switch receives the signal, and the loading and unloading translation mechanism works. First, the lifting cylinder is jacked up, after the steel pipe is in place, a signal is sent, the piston rod of the translation cylinder is extended, the material is translated to the center of the two rollers, and the signal is given, and the piston rod of the translation cylinder is contracted into position. The loading and lowering translation mechanism returns to the original position and waits for the next instruction.
2. The double-duck drive system is divided into three zones, namely the feed zone, the heating zone and the discharge zone. There are 12 sets of double-drum drive system in the feeding area. There are 14 sets of double-duck drive system in the heating zone. There are 12 sets of double-duck drive system in the discharge area, totaling 38 sets. Each zone is equipped with a set of frequency converters and a motor with an adjustable angle. The steel pipe is controlled by the feeding rod to make the steel tubes meet end to end. When the end of the steel pipe is about to leave the front port of the first heating furnace, if there is no material, the feed detection switch will send a signal and the separation mechanism will work once. If the clamp (the steel pipe is stationary), the feed detection switch will give an alarm signal.
3. The speed of the double-stick transmission system in the heating zone is a predetermined value according to the specifications of the steel pipe. When the steel pipe passes through the first set of inductors (750KW), the temperature of the steel pipe should be heated to about 500 °C (where infrared temperature is set) Instrument), when the steel pipe enters the 100KW sensor, the temperature of the steel pipe should be heated to 930 ° C (here, there is an infrared thermometer), the steel pipe enters the water spray area, the spray in-position detection switch is opened, and then the spray In the shower area, the spray in-position detection switch is turned on, and then enters the spray drying zone. The spray dry area in-position detection switch is turned on, and finally enters the tempering sensor (750Kw), and an infrared thermometer is also provided at the exit of the tempering sensor. Finally check the tempering temperature of the steel pipe.
4. The speed of the double-claw transmission system in the discharge area is consistent with the transmission speed of the heating zone. However, when the tail end of the steel pipe is about to leave the last set of double-bars in the heating zone, the discharge detection switch sends a signal, and the discharge zone doubles. The driving speed of the roller is accelerated, and the heated steel pipe is quickly pulled out, so that the distance between the first and last steel pipes is pulled apart, and finally the steel pipe is blocked by the material blocking mechanism, and a signal is sent, and the lifting and lowering mechanism is operated.
5. When the discharge lifting and lowering mechanism receives the signal, firstly, the piston rod of the lifting cylinder is contracted, and the feeding mechanism simultaneously lifts the steel pipe after the tempering. After the position, the piston of the translation cylinder is extended to reach the end point (ie, the position of the two-way cooling bed) ). The cold bed dragging device and the rotating device automatically stop working at the same time. When the discharging lifting and lowering mechanism smoothly puts down the material, the two-way cooling bed is restarted. The discharge lifting and lowering mechanism returns to the original position and waits for the next instruction.
6. The working condition of the steel pipe in the two-way cold bed is: stepping and rotating. When the step reaches the end point, the steel pipe rolls onto the collecting gantry (when the temperature of the steel pipe ≤ 150 ° C) is blocked by the hardness device fork. If hardness is required, it can be manually performed. After the hardness is completed, the two-position five-way electromagnetic is turned on, the pneumatic piston rod contracts, and the steel tube rolls to the end of the collecting stand and is stopped. After the material is full, it will be tied up by hand and continue to the next process.
Fourth, safe operation instructions
1. Maintain good lubrication of each rotating part, and must load oil once per shift;
2. Each grounding conductor should be inspected frequently and kept well grounded;
3. Always check the fastening bolts for looseness;
4. Check the oil quantity of the fuel tank, and it should be replenished in time when it is lower than the liquid level;
5. Always check the high-pressure hose, if it is damaged, it should be replaced in time;
6. The hydraulic oil should be kept clean and replaced regularly. The oil tank and filter should be cleaned every time the oil is changed.
7. The backup pump of the water supply system should be exchanged and used regularly to avoid rusting if not used for a long time;
8. Identify and train full-time operators, untrained personnel are not allowed to work;
9. When the cooling water pressure and water temperature exceed the set value, the fault must be eliminated before continuing operation.
10. Protection against electric shock
a. Protection shall comply with the relevant provisions of GB J65-83 "Code for Design of Grounding for Industrial and Civil Power Equipment";
b. For other protections, operators should wear personal protective equipment such as insulated gloves, insulated shoes, protective caps and goggles, and protect them from moisture and moisture to prevent accidents from electric shock.
c. When servicing power supplies, capacitor cabinets, and furnaces, turn off the power and do not work.