Location: New Jersey, USA
Introduction
The automated heat treatment cell performs numerous unmanned heat treatment cycles, using a programmed controller and is fully enclosed. It represents a change in mind set, for no longer is the heat treatment a series of separate tasks and equipment but rather another manufacturing cell with the cleanliness and automation that the name suggests.
Scope
Design, manufacture, shop test, install and commission an automated heat treatment cell capable of a wide range of surface treatments and hardening for actuator components.
The automated heat treatment cell is comprised of two high temperature fluidised bed furnaces, oil quench, tempering furnace, alkaline wash and slow cool, plus an automated transporter that travels above the furnaces on a rail system, which is all completely enclosed for cleanliness and safety. All the equipment is computer controlled and fully programmable.
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Retort size |
500mm dia x 1200mm deep (20” dia x 48” deep) |
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Maximum load |
400kg (900lbs) |
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Maximum temperature |
1066oC (1950oF) |
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Process gases |
Air Nitrogen Ammonia Natural gas
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Heating |
Electrical |
The main furnace line is comprised of two FH512M fluid beds, one AR512T air recirculation furnace, and a number of cooling, washing and quench tanks. The furnaces are capable of performing a variety of heat treatments from hardening and tempering through to the surface treatments such as carburising and nitrocarburising.
Fluidised beds offer a number of advantages over conventional furnaces including low operating and maintenance costs, excellent temperature uniformity and heat transfer as well as ease of operation and flexibility. All the furnaces and quench tanks are mounted on a base frame and positioned in a single line.
Mounted above the furnace line is a rail system holding the transporter unit. The transporter can pick up loads from one stations and transfer to another using a series of drive motors and pneumatic cylinders. The drive motors are variable speed, meaning that loads going into a furnace can be moved slowly whilst loads being quenched can be moved at a much faster rate.
At the end of the furnace line are loading bays capable of holding three different loads. All this is enclosed in a sheetmetal panel to ensure a clean and safe work environment.
Both furnace operation and transporter movement is controlled by an Allen Bradley PLC. The operator interface is a computer screen running CITECT software making it very user friendly. All the electrical controls are housed in the one panel. Numerous safety features are incorporated into the design to protect both operators and the integrity of the work being processed.
Atmosphere gas monitoring includes closed loop fluidising gas control and electronic atmosphere gas flow rate information. The software package is capable of accepting up to 300 different recipes and processing components unmanned.