鋁管感應加熱連續(xù)退火生產(chǎn)線2020新型

一、整機機結(jié)構

連續(xù)在線退火爐由放料機構、夾矯主機、加熱中頻爐、保溫用中頻爐、淬火及吹干機構、張緊機構、收料機構及輔助系統(tǒng)測速裝置、計算機控制核心系統(tǒng)組成。在連續(xù)在線退火機組中，感應加熱爐是整機正常運行的核心，計算機自動控制系統(tǒng)為控制核心。

工藝流程：放料筐就位—鋁管經(jīng)活套檢測機構穿過井字輥至前夾送機構—清洗外壁—吹干—水平矯直—垂直矯直—垂直夾送—感應加熱—保溫—淬火冷卻—吹干—夾送張緊機構—收料

控制制系統(tǒng)結(jié)構及特點 鋁管感應加熱連續(xù)退火生產(chǎn)線為全自動工作方式，在完成引管工作后，操作人員只需在線設置退火線速度和退火溫度，其它所有操作均由計算機自動實現(xiàn)。本控制系統(tǒng)有以下特點：

(1)收、放料機構和夾矯機構的驅(qū)動系統(tǒng)采用系列矢量控制器，張緊機構的驅(qū)動系統(tǒng)采用直流控制器。

(2)計算機系統(tǒng)采用中國臺灣研華。操作系統(tǒng)xp可以實現(xiàn)聯(lián)網(wǎng)控制。

(3)人機接口采用三星23寸LED屏觸摸屏十分方便操作和調(diào)試人員進行系統(tǒng)監(jiān)控。

(5)應用軟件除常規(guī)的邏輯控制外，管材感應連續(xù)退火控制器應用軟件，具有以下功能：

①P—V(功率一速度)自動跟隨功能。根據(jù)管材規(guī)格和退火工藝要求，中頻電源

輸出功率自動跟隨鋁管速度變化，保證退火溫度穩(wěn)定。L400型鋁管速度可在20一400m/min連續(xù)可調(diào)。

②采用實測模塊計算中頻電源的控制電壓。該法簡單可靠，不受測溫度裝置、

測功率系統(tǒng)工作狀態(tài)的影響。*的功率控制模型保證了退火爐的控制精度。

③鋁管的微張力控制功能。鋁管在加熱過程中實現(xiàn)自動建張，從而使鋁管在退火

狀態(tài)下不被拉伸或堆縮。

④收、放料速度補償功能。用活套檢測和收、放料速度補償計算，保證料筐的收、

放料速度跟隨退火鋁管的線速度變化，且放料穩(wěn)定、收料均衡。

三、設備主要技術參數(shù)

中頻加熱爐介紹：

此加熱裝置，是我公司專為鋁管在線退火而設計的，針對其在運動中進行連續(xù)加熱及被加熱工件為鋁材的特點，在系統(tǒng)設計中對電源、感應器各參數(shù)應做特殊設計，整套系統(tǒng)采用兩套400KW/6KHZ電源進行加熱，感應器外部制作成鋁質(zhì)封閉外殼,內(nèi)充保護性氣體(氮氣)以防鋁管加熱氧化,此系統(tǒng)具有以下特點：

1.1中頻電源為400KW/6KHz。由于功率較大，頻率較高，電源設計有一些特殊要求。這些將在電源的描述中詳細說明。

1.2中頻電源和感應器均采取閉環(huán)冷卻塔冷卻方式，使設備的體積較小，容易安裝。

1.3自動連續(xù)生產(chǎn)，可根據(jù)不同工件參數(shù)自動調(diào)整生產(chǎn)速度。

1.4生產(chǎn)線傳輸滾道采用變頻調(diào)速，加上計算機控制可實現(xiàn)溫度、速度、功率等的閉環(huán)控制。

2、系統(tǒng)設備運行方案：

2.1系統(tǒng)功率的選擇:

加熱總功率的選擇根據(jù)貴方400m/min的要求，選擇為400KW。

2.2方案的選擇：

根據(jù)加熱工況為快速運行中加熱的設備使用特點，由于感應加熱的提溫速度過快，無保溫過程，從而影響鋁管晶粒組織的細化過程，故該套系統(tǒng)采用脈沖式分段連續(xù)加熱的方式，該種加熱方式適用于連續(xù)式加熱，是一種國外目前**的加熱方式，這種加熱方式可使鋁管在經(jīng)過無爐體部分有短時間的保溫過程，這個保溫過程在鋁管的退火工藝中保證了其晶粒組織的細化過程，使其內(nèi)部的晶粒細小、均衡，從而可使鋁管退火后能達到貴公司的加工工藝要求。同時對于在加熱爐體內(nèi)的加熱鋁管不會引起軸向上的過大溫差從而在某種程序上能克服熱應力所造成的微觀裂紋。

2.3設備配置及加熱工藝過程的實現(xiàn)：

將所需電源400KW/6KHZ為兩臺加熱爐體供電，兩臺加熱爐體對鋁管進行加熱，每臺爐體對鋁管進行一次快速提溫后，經(jīng)過短時間的保溫過程，這個過程為無加熱過程，為防止進入下一臺感應爐時鋁管低頭而無法對準，中間設有機械滾輪裝置定位；為了防止鋁管加熱過程的氧化，將兩臺爐體及導位部分裝入一臺密封的外殼之中，其中通入惰性氣體；每臺爐體的長度為400MM，機械滾輪裝置與爐體之間的距離為單邊20MM，爐體部分合計長度為800MM，考慮外殼占用部分空間，該加熱部分總長度需1200MM即可。

將兩臺爐體和一套機械滾輪裝置底座均固定在同一個爐體底座上，爐體的外殼為硬質(zhì)鋁合金，可同時起到保護氣體密閉和磁屏蔽作用，使機架、滾輪等不被漏磁感應加熱；爐體外殼設計為可拆卸式，對于爐體的檢修、機械滾輪裝置的更換均提供了方便。

Aluminum tube induction heating continuous annealing production line

First, the machine structure

he continuous in-line annealing is composed of a discharging mechanism, a clamping and fixing main machine, a heating intermediate frequency , an intermediate frequency for heat preservation, a quenching and drying mechanism, a tensioning mechanism, a receiving mechanism, an auxiliary system speed measuring device, and a computer control core system.In the continuous online annealing unit, theinduction heating is the core of the normal operation of the whole machine, and the computer automatic control system is the control core.

Process flow: the discharge basket is in place—the aluminum tube passes through the nesting roller to the front pinch mechanism through the loop detection mechanism—cleaning the outer wall—drying—horizontal straightening—vertical straightening—vertical pinching—induction heating—insulation— Quenching and cooling - blow drying - pinch tensioning mechanism - receiving

Control system structure and characteristics he aluminum tube induction heating continuous annealing production line is a fully automatic working mode. After the completion of the guiding work, the operator only needs to set the annealing line speed and the annealing temperature online, and all other operations are automatically realized by the computer.his control system has the following characteristics:

(1)he drive system of the receiving and discharging mechanism and the clamping mechanism adopts a series of vector controllers, and the driving system of the tensioning mechanism adopts a DC controller.

(2) hecomputer system uses aiwan Advantech.he operating systemxpcan implement networked control.

(3) hehuman-machine interface adopts Samsung's23-inchLEDscreen touch screen, which is very convenient for operation and debugging personnel to carry out system monitoring.

(5)Application software In addition to the conventional logic control, the tube induction continuous annealing controller application software has the following functions:

1P—V (power-speed)auto follow function.Intermediate frequency power supply according to pipe specifications and annealing process requirements

he output power automatically follows the change in the speed of the aluminum tube to ensure that the annealing temperature is stable.L400type tubes20ataspeed400m / mincontinuously adjustable.

2 Use the measured module to calculate the control voltage of the intermediate frequency power supply.he method is simple and reliable, and is not subject to temperature measurement devices.

Measure the impact of the operating state of the power system.he precise power control model guarantees the control accuracy of the annealing .

3 aluminum tube micro tension control function.he aluminum tube is automatically built during the heating process, so that the aluminum tube is annealed.

Not stretched or shrunk in the state.

4 receiving and discharging speed compensation function.Use the loop detection and collection and discharge speed compensation calculation to ensure the receipt of the basket,

he discharging speed follows the linear velocity of the annealed aluminum tube, and the discharging is stable and the receiving is balanced.

hird, the main technical parameters of the equipment

Intermediate frequency heating introduction:

his heating device is designed for on-line annealing of aluminum tubes. It is designed for continuous heating and heating of workpieces in aluminum. In the system design, special parameters should be made for the parameters of power supply and inductor. he whole system isheatedby two sets of400KW/6KHZpower supply. he outside of the inductor is made of aluminum closed casing,which is filled with protective gas(nitrogen)to prevent heating and oxidation of the aluminum tube.his system has the following characteristics:

1.1 heintermediate frequency power supply is400KW/6KHz.Due to the high power and high frequency, the power supply design has some special requirements.hese will be detailed in the description of the power supply.

1.2 heintermediate frequency power supply and the sensor adopt the closed-loop cooling tower cooling mode, which makes the equipment small in size and easy to install.

1.3Automatic continuous production, the production speed can be automatically adjusted according to different workpiece parameters.

1.4 heproduction line transmission raceway adopts frequency conversion speed regulation, and computer control can realize closed-loop control of temperature, speed and power.

2, system equipment operation plan:

2.1System power selection:

he total heating power is selected according to yourrequirementsof400m/minａnd is chosen to be400KW.

2.2Choice of the program:

According to the heating condition, the characteristics of the equipment used for heating in the fast operation, because the heating speed of the induction heating is too fast, there is no heat preservation process, thus affecting the refinement process of the aluminum tube grain structure, so the system adopts pulse type segmentation continuous he heating method is suitable for continuous heating. It is the most advanced heating method in foreign countries. his heating method can make the aluminum tube have a short-term heat preservation process in the non- part. he annealing process of the aluminum tube ensures the refinement process of the grain structure, so that the internal crystal grains are fine and balanced, so that the aluminum tube can be tempered to meet the processing requirements of your company.At the same time, the heated aluminum tube in the heating does not cause an excessive temperature difference in the axial direction, so that the micro crack caused by the thermal stress can be overcome in some procedures.

2.3Equipment configuration and realization of the heating process:

he required power supply400KW/6KHZis used to supply two heating bodies, and two heating bodies are used to heat the aluminum tubes. After each body is rapidly heated by the aluminum tubes, after a short period of heat preservation process, the process is here is no heating process. In order to prevent the aluminum tube from falling down when entering the next induction , it is impossible to align, and the mechanical roller device is positioned in the middle; in order to prevent oxidation of the aluminum tube heating process, the two bodies and the guiding portion are loaded into one In the sealed outer casing, inert gas is introduced into it; the length of each body is400MM, the distance between the mechanical roller device and the body is20mm onone side, and the total length of the body is800MM. Considering the space occupied by the outer casing he total length of the heating portion needs to be1200 MM.

he two bodies and a set of mechanical roller device bases are fixed on the same body base. he outer shell of the body is made of hard aluminum alloy, which can simultaneously protect the gas sealing and magnetic shielding, so that the frame, the roller, etc. It is not heated by magnetic flux leakage; the shell of the body is designed to be detachable, which provides convenience for the inspection of the body and the replacement of the mechanical roller device.

1488

430

哪個廠家的質(zhì)量好?生產(chǎn)廠家西格馬質(zhì)量好，售后完善。