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Calibration of Unstable Heat Treatment Process Parameters: Dual Assurance of Intelligent Monitoring and Equipment Calibration

2026-01-23

Calibration of Unstable Heat Treatment Process Parameters: Dual Assurance of Intelligent Monitoring and Equipment Calibration

Unstable process parameters will lead to fluctuations in product performance. For example, a furnace temperature fluctuation of ±5℃ can result in a workpiece hardness deviation of more than HRC5, and a 10% deviation in heating time will cause insufficient austenitization or coarse grains, directly impairing product consistency. The main causes include deteriorated accuracy of temperature control instruments, aging of heating elements, sensor malfunctions, and fluctuations in power supply voltage, among others.

The core of the stability improvement solutions is as follows:

Establish a regular calibration system: calibrate temperature control instruments and thermocouples on a monthly basis by conducting comparisons with standard thermometers to ensure the temperature measurement accuracy is ≤±1℃; detect the resistance value of heating elements every 6 months and replace them immediately if the deviation exceeds 10% to avoid uneven power output.
Upgrade the intelligent monitoring system: install a PLC control system and data acquisition modules to conduct real-time monitoring of key parameters such as furnace temperature, holding time and cooling rate; set upper and lower limit alarm thresholds (e.g., an automatic alarm is triggered if the furnace temperature deviation exceeds ±3℃), and realize automatic data storage for traceability.
Optimize power supply and equipment maintenance: equip with voltage stabilizers to stabilize the input voltage (control the fluctuation range within ±5%); inspect the terminal blocks of the heating circuit on a weekly basis and remove oxide layers to ensure good electrical contact; conduct a comprehensive overhaul of the transmission system and cooling system every quarter to prevent abnormal parameters caused by mechanical failures.

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Calibration of Unstable Heat Treatment Process Parameters: Dual Assurance of Intelligent Monitoring and Equipment Calibration

Calibration of Unstable Heat Treatment Process Parameters: Dual Assurance of Intelligent Monitoring and Equipment Calibration