Industrial Electrical Resistance Support Roller

Conveyor Mesh Belt Furnace , Heat Treatment Furnace

1.Buyer Requirement

1.1 product: steel nails, self-tapping screw;

1.2 process: carburizing, bright quenching and tempering;

1.3 productivity: quenching: 500-1000kg/h;

2. Specification

According to the buyer’s requirement, we recommend our customer to

choose 800*10000mm support roller type electrical mesh belt furnace.

3. Equipment General Introduction and Main Features

1 General Introduction

1.1 The heat treatment line combines the advanced technologies

from Taiwan. Its key parts are imported from overseas.

1.2 The production line is comprised of magnetic belt charging machine,

pre-cleaning machine, support roller quenching furnace, quenching tank,

oil removing stand, post-cleaning machine, support-roller mesh belt

tempering furnace, and electrical control system.

Features:

2.1 To meet the production needs of fastening parts, the furnace employs

Taiwan technology, and improves its energy-saving effect in the area of

refractory lining.

2.2 The production line employs low-voltage heating through the transformer

to prolong the service life of the heating tubes.

2.3 The mesh belt is supported by the support rollers with synchronized movement

so that the mesh belt bears a minimum tension.

2.4 The rollers are supported by special high-pressure sealed bearing.

2.5 The mesh belt is designed with abnormal transportation alarm device to

assure the stable movement of the mesh belt.

2.6 The drip-in atmosphere is gasified by a gasifier and then sent into the furnace.

The atmosphere is monitored and controlled continuously by an oxygen probe.

2.7 The hot mesh belt returns back to the entrance of the furnace and preheats

the cold partss, which saves energy greatly.

4. Production Line Basic Parameters

5. Technical Parameters 

6. Production Line Power and Energy Consumption

6.1 power

Heating power: 380V±10%, 3 phase, AC, 50HZ;

Measuring and control system: 220V±10%, 50HZ

Heating system:about 745kW

Driving system power and other consumption spots: about 40kW

Power supply of the whole line: about 785W

Power consumption at normal working: about 420kW

6.2 atmosphere inlet pipe parameters

Methanol inlet pipe: 4-6 L/h ; ≥0.04 Mpa;

Propane inlet pipe: automatic control with supply ≤500L/h;

supply pressure ≥0.04Mpa;

Ammonia inlet pipe: 3m3/h;

6.3 cooling water

Water quality: according to state standard low-calcium

industrial circulating water;

Suspended substance: max 10mg /L;

Filter mesh belt hole size: max 0.3mm;

Inlet temperature: (max) 30℃(in summer)

Inlet temperature: (min)5℃ (in winter)

Temperature difference: 10℃

Inlet pressure: 0.2 Mpa

Max water consumption: about 100m3/h (circulating use)

6.4 Supplementary Equipment ( supplied by the buyer)

The cooled water tank and cooling tower are usually mounted

outside the workshop

but near the production line. The cooling power capacity should

be ≥100m3/h.

7. Technical Specification Per Unit

Magnetic Belt Charging Machine

The charging machine is comprised of tip frame, vibration silo,

magnetic belt conveyance system, and driving system. The

machine frame is made from sectional steel and steel plates.

1 Chain and sprocket wheel: P=25.4mm, 1 set;

2 reducing gear, 0.55kw (VF speed regulation), 1 set

3 magnetic belt: 900*3450*1/2mm (SUS304) 1 piece

4 Strong force magnetic steel: 28*26*8 1 group;

5 Vibration motor: 150W, 1 set;

6 hydraulic station: 16Mpa/cm2 2.2kw, 1 set;

7 hydraulic oil cylinder: ￠80*800mm 1 set;

Mesh Belt Type Pre-cleaning Machine

The pre-cleaning machine is of the immersion type. It has 3 working

positions which are rinsing, soap water jetting, and strong-air drying.

The charging machine is equipped with the strong force nozzle. And it

is flanked by one water oil separation tank and one oil collection tank.

The oil collected could be used.

tank body

The cleaning tank body is fabricated from steel plates and sectional

steel which are welded together.

2 mesh belt driving device

Mesh belt: 800*7200*1.5/2.5mm 1 piece;

Chain and sprocket wheel : P=25.4mm, 1 set;

　Reducing gear: 0.55kW, 1 set;

3 cleaning tank volume: 2000L;

4 cleaning jetting pump: 2.2kW 1 set;

Copper nozzle, several; 　

5 heating device: 380V/4kW, 6 pieces, 24KW in total;

6 oil and water separation tank

　Oil and water separator, 1 set;

Gear motor, 0.37kW 1 set;

7 drying fan at the exit, air conditioning fan, 1 set;

8 temperature controller, RKC, 1 set;

Thermal resistor, PT100, 1 piece;

9 Driving detection device, Omron, 1 set;

10 liquid valve d=15 1 piece;

11 Overloading protector, 1 set;

Vibration Distribution Machine

1 vibration silo 1piece;

2 vibration motor 150W, 2 sets;

Mesh Belt Quenching Furnace　　

The quenching furnace is the key part of the production line.

It is comprised of furnace shell, front machine stand, heat

preservation material, heating device, temperature control device,

and atmosphere supply device.

1 Main parameters:

　Mesh belt width :800mm

　Working area length: 10000mm

Entrance length: 2000mm

Preheating area length: 1500mm

　Temperature control: 6-zone PID control;

　Rated power: 420KW

Furnace temperature uniformity:≤±5℃　temperature uniformity for the

same section:≤±3℃; furnace outer wall temperature rise: ≤50℃

2 mesh belt driving device

2.1 The parts are conveyed through the mesh belt.

2.2 The mesh belt is supported by the support rollers with synchronized

movement. The mesh belt is of the front-driven type, and thus bears a

minimal tensile force at high temperature.

2.3 mesh belt driving speed:50～220mm/min, inverter control;

2.4 mesh belt: 800*26000*2/3mm; 1 piece;

2.5 support rollers

Preheating upper rollers, ￠50 SUS304 5 pieces;

Preheating lower rollers, ￠87mm SUS304 3 pieces;

Upper rollers, ￠50mm SUS310 35 pieces

Lower rollers, ￠87mm SUS310 12 pieces

Rear driving roller, ￠203mm SUS310 1 piece

Bearing UCFL207 110 sets;

2.6 chain and sprocket wheel, P=19.05mm, 1 set

2.7 reducer, 0.75kW 1 set;

2.8 inverter, Mitsubishi, 1 set;

2.9 mesh belt driving detection device, Omron, 1 set;

3 heat preservation material

3.1 The roof wall is lined with 1400 high temperature silicate aluminum

fiber and 1260 silicate aluminum cera blanket, which are fixed by ￠8mm

rods and press plate made of SUS310S.

3.2 The furnace side walls are lined with Isolite anti-carburizing bricks, heat

preservation bricks and heat preservation boards. The lining thickness is 395mm.

3.3 The refractory adhesive is P-150 (Japan brand). It has the characteristics

of stronger bonding effect at higher temperature. It resists a max temperature

of 1600 degree celcius.

4　heating device: electrical heat radiation tubes.

4.1 The electrical heating tubes are installed in the upper and lower wall of the

hearth. The heating system works with low voltage power supply, and the

furnace doesn’t need to be stopped when replacing the heating tubes.

4.2 electrical heat radiation tubes, 66 sets;

a) outer pipe: ￠122*1425*4mm (SUS310S), 66 pieces;

b) heating tube core: OCr21Al6Nb, 66 sets;

c) insulation parts (corundum): 66 sets;

4.3 thermal couple WRN430 K type, 6 pieces;

4.4 Each zone is set with an independent transformer. The heat radiation tube

is in parallel connection, and doesn’t interfere with each other. The heat

radiation tubes are easily maintained.

Transformer, 380V/56V, 6 sets;

Mixing fan (NSK bearing with water cooling system), 4 sets;

vanes (shaft and vanes), 4 pieces;

bearing, NSK, 8 sets;

motor, 1.5kw, 4 sets;

6 exhaust fume device ( removing and burning the fume of the furnace

and the oil tank)

Air pump, 250W, 1 set

7 water tank at the furnace mouth with inside SUS304 layer, 1 set;

8 furnace door

a) movable furnace door at the furnace mouth, 1 set;

b) soft curtain door inside the furnace, 4 groups;

9 dust removal hole, 12 pieces;

The dust holes are set at the lower part of the two side walls of the preheating

and the heating section. The dust hole is blocked with a plug made of the

heat preservation fiber and cover plate. The plug is fixed by the lever mechanism,

and is easy to be removed.

10 The furnace door is also equipped with 1 fire curtain to heat the cleaning

liquid in the cleaning tank.

11 atmosphere supply device

atmosphere supply: drip-in type: methanol+propane+ammonia;

11.1 Atmosphere control:

Oxygen probe, marathon, USA, 2 pieces;

Carbon potential controller, Eurotherm, 2 sets;

Proportional valve, Burket, Germany, 5 sets;

Methanol flow meter, 5 sets;

Propane flow meter, 4 sets;

Ammonia flow meter, 4 sets;

Propane flow meter, 2 sets;

Reference air flow meter, 4 sets

Air pump, 35W, 2 sets