※ Equipment Use
The new generation of wind power gear ion nitriding furnace is an advanced equipment used in the field of wind power gear manufacturing for ion nitriding treatment of wind power gear. The following are introduced from the aspects of its characteristics and technological innovation:
※ Features
· High efficiency and energy saving: The use of advanced heating technology and insulation materials, can effectively reduce heat loss, improve energy efficiency, shorten nitriding treatment time, thus reducing production costs. For example, the intelligent ion nitriding equipment of Qingdao Fengdong has a heating rate of 3-4 times that of traditional furnace type and saves more than 20% of electricity.
· Good treatment effect: uniform and dense nitriding layer can be obtained on the surface of wind power gear, which can significantly improve the hardness, wear resistance, corrosion resistance and fatigue resistance of gear, and prolong the service life of gear. Such as the new large-scale pulse power supply ion nitriding furnace, the nitriding layer depth can reach 0.6-0.8mm, and the parts deformation is small.
· high degree of automation: equipped with advanced control system, it can realize the precise control and real-time monitoring of the temperature, pressure, time and other parameters of the nitriding process, and can automatically execute the process, reduce manual intervention, improve production efficiency and product quality stability. For example, the equipment of Qingdao Fengdong can store 999 process curves, and the system automatically executes according to the process setting parameters.
· Excellent environmental performance: less pollutants such as waste gas, waste water and waste residue are generated in the operation process, which meets the environmental protection requirements and reduces the pollution to the environment. At the same time, due to the remarkable energy-saving effect, it also indirectly reduces carbon emissions.
※ Key technology innovation
· Power technology: The use of a new generation of frequency conversion full inverter pulse power supply, the highest frequency can reach 20kHz, the maximum current 1000A, intelligent parameter control, small size and energy saving, can provide stable and efficient ion nitriding energy, accurate control of ion nitriding process.
· Temperature control technology: Equipped with a multi-point temperature measurement and control system, multiple temperature monitoring points are set in the furnace to realize the comprehensive monitoring of the working temperature inside the furnace, and combined with the partition temperature control technology outside the furnace, the temperature uniformity can reach ±5℃, ensuring the same nitriding effect in all parts of wind power gear.
· vacuum system: Optimized vacuum system, such as the use of two-stage vacuum unit (rotary vane pump + Roots pump), pumping speed increased by 30%, furnace pressure automatically adjusted by PID parameters, stable and no fluctuation, to provide a good vacuum environment for ion nitriding, help to improve the quality and efficiency of nitriding.
· Cooling system: rapid cooling system is an important part of the new generation of ion nitriding furnace, such as the furnace is equipped with stirring fan, each heating area is equipped with an independent cooling fan, after nitriding is filled with nitrogen for rapid cooling, cooling efficiency is 3-4 times that of traditional furnace, can effectively control the cooling speed of the gear, to avoid deformation or cracking caused by uneven cooling problems.
Technical parameter
| Operating temperature |
Generally 500-540 ° C, the nitriding hardness of different materials has the best corresponding value between the temperature, usually at 450-540 ° C, higher than 590 ° C, the hardness will be significantly reduced due to nitride accumulation. |
| Rate of warming |
Generally 150-250℃/h, in order to reduce the deformation of the workpiece, the temperature should not be too fast |
| Furnace gas pressure |
After empty furnace or workpiece loading, the air pressure should be able to reach 6.67Pa below, in actual operation, the working air pressure is generally between 133-1066Pa, commonly used 266-800Pa |
| voltage |
The voltage of the insulation stage is generally 500-700V |
| Current density |
Generally between 0.5-20mA/cm², commonly used 0.5-3mA/cm² |
| Nitriding holding time |
Depending on the nitriding material and the thickness and hardness requirements of the nitriding layer, when the depth of the nitriding layer is 0.2-0.5mm, the general insulation is 8-20h |
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