New-Generation Ion Nitriding Furnaces for Wind Power Gears

※ Equipment Purpose

※ Features

• High Efficiency & Energy Saving: Adopting advanced heating technology and thermal insulation materials, it effectively reduces heat loss, improves energy utilization efficiency, shortens nitriding time, and thus lowers production costs. For example, the intelligent ion nitriding equipment developed by Qingdao Fengdong has a heating rate 3-4 times that of traditional furnaces and saves more than 20% of electricity.
• Excellent Treatment Effect: It enables the surface of wind power gears to form a uniform and dense nitrided layer, significantly enhancing the gears’ hardness, wear resistance, corrosion resistance, and fatigue resistance, while prolonging their service life. For instance, the new large-scale pulse power ion nitriding furnace by Saifeisi can achieve a nitrided layer depth of 0.6-0.8 mm with minimal part deformation.
• High Degree of Automation: Equipped with an advanced control system, it can realize precise control and real-time monitoring of parameters such as temperature, pressure, and time during the nitriding process. It can also automatically execute process programs, reducing manual intervention and improving production efficiency as well as the stability of product quality. For example, the equipment by Qingdao Fengdong can store 999 process curves, and the system automatically executes operations according to the preset process parameters.
• Superior Environmental Performance: It generates less pollutants such as waste gas, wastewater, and residue during operation, meeting environmental protection requirements and reducing environmental pollution. Meanwhile, its significant energy-saving effect also indirectly reduces carbon emissions.

※ Key Technological Innovations

• Power Supply Technology: It adopts a new-generation variable-frequency full-inverter pulse power supply, with a maximum frequency of up to 20 kHz and a maximum current of 1000 A. The parameters are intelligently controlled, and the power supply is small in size and energy-saving. It can provide stable and efficient ion nitriding energy to precisely control the ion nitriding process.
• Temperature Control Technology: Equipped with a multi-point temperature measurement and control system, it realizes comprehensive monitoring of the working temperature inside the furnace by arranging multiple temperature monitoring points. Combined with the external furnace zone-controlled temperature technology, the temperature uniformity can reach ±5℃, ensuring consistent nitriding effects on all parts of the wind power gear.
• Vacuum System: The optimized vacuum system (e.g., adopting a two-stage vacuum unit consisting of a rotary vane pump and a roots pump) increases the pumping speed by 30%. The furnace pressure is automatically adjusted via PID parameters, maintaining stability without fluctuations. This provides a good vacuum environment for ion nitriding, helping to improve nitriding quality and efficiency.
• Cooling System: The rapid cooling system is a key component of the new-generation ion nitriding furnace. For example, the furnace is equipped with a stirring fan, and each heating zone is fitted with an independent cooling fan. After nitriding, nitrogen is filled for rapid cooling, with a cooling efficiency 3-4 times that of traditional furnaces. This can effectively control the cooling rate of gears and avoid problems such as deformation or cracking caused by uneven cooling.

※ Technical Parameters