Wuxi Wondery Industry Equipment Co., Ltd

I. Equipment Overview & Functional Description This Electric Bogie Hearth Heat Treatment Furnace (Model: RT2-220-9) is an industrial batch-type furnace designed for annealing, normalizing, and quenching heat treatment processes of metal and alloy components under $1100^circtext{C}$ in ambient air. The equipment provides an effective internal working space of $2500 times 1300 times 900text{ mm}$ ($text{L} times text{W} times text{H}$), a rated heating power of 220 kW, and a maximum loading capacity of approximately 2 Tons. The heavy-duty shell frame is welded from $3text{ mm}$ steel plates and 10–14# steel columns to form a rigid grid structure, coated with anti-corrosion and high-temperature resistant paint. The furnace lining features a full ceramic fiber folded block structure (Shandong Luyang 1260 high-purity ceramic fiber, density $ge 230,text{kg/m}^3$, total lining thickness $325text{ mm}$), offering minimal thermal conductivity, excellent resistance to thermal shock, and high durability. The bogie movement is driven by a $1.2text{ kW}$ cycloidal pinwheel reducer paired with ZG55# cast steel wheels and heavy-duty bearings for smooth traversal. The furnace door mechanism utilizes a 1-Ton electric hoist for vertical movement and secures a tight seal through a self-weight clamping mechanism, eliminating the need for counterweights or floor pits. The entire process automation is managed via a smart HMI panel, ensuring complete operation safety and efficiency for heavy workloads. II. Technical Specifications & Integrated Component Configuration 1. Thermal & Electrical Specifications Rated Power & Power Regulation: 220 kW rated heating power, driven by a Jiangsu Danxiang SCR Power Regulator providing 1%–100% stepless, high-precision adjustment for optimized energy management. Operating Supply: 3-Phase $380text{V} / 50text{Hz}$ industrial power supply. Temperature Capabilities: Maximum design temperature of $950^circtext{C}$ with a continuous normal working temperature of $850^circtext{C}$. Fast thermal response enables an empty furnace heating time of $< 1text{ hour}$. Control Accuracy & Uniformity: Divided into 2 independent temperature control zones, delivering a strict temperature control accuracy of $pm 1^circtext{C}$ and a thermal uniformity within $pm 10^circtext{C}$ inside the effective workspace. 2. Materials & Heavy-Duty Hardware Integration High-Performance Heating Elements: Engineered with premium Beijing Shougang high-resistance 0Cr25Al5 alloy strips in a corrugated layout, anchored firmly on side walls and the bogie surface via specialized ceramic anchor bolts. Full-Fiber Energy-Saving Lining: Built with high-purity Shandong Luyang 1260 ceramic fiber modules (density $ge 230,text{kg/m}^3$, total lining thickness $325text{ mm}$) and Henan Baiwei high-grade refractories, keeping the outer side-wall temperature rise under $< 40^circtext{C}$. Heat-Resistant Hearth Plates: The bogie is armored with 30 mm thick CrMnN heat-resistant steel plates to withstand heavy impact and prevent damage to bottom heating coils. Smooth Bogie Drive System: Driven by a Changzhou Weiyikang 1.2 kW cycloidal pinwheel reducer coupled with ZG55# cast steel wheels and heavy-duty bearings for reliable traversal. 3. Smart Controls & Electrical Hardware HMI & Temperature Controller: Features a Shimaden (Japan) SRS3 high-precision programmable controller paired with an MCGS 10.1-inch color HMI touchscreen for real-time trend visualization, formula storage, and diagnostics. Low-Voltage Electricals: Assembled with reliable Delixi low-voltage electrical switchgears and safety breakers to guarantee complete interlock protection. III. Electrical Control & Smart Logic Interlocking Temperature Control System: Integrated with Japanese Shimaden SRS3 intelligent programmable controllers and SCR power regulators utilizing time-proportional module firing with smooth manual/automatic transfer. Human-Machine Interface (HMI): Equipped with a 10.1-inch color touchscreen capable of real-time & historical trend logging, recipe storage/loading, USB data export, screen capturing, and over-temperature alarm logic. Safety Interlocking Network: Bogie motion is disabled during active heating cycles; Heating can only activate when the furnace door is fully closed; The bogie can only travel in/out when the door reaches its upper limit position; Travel limits for both the hoist and bogie are guarded by position limit switches. IV. On-Site Production Operational Process Flow System Initialization: Power on the main control cabinet, inspect utility connections and interlock statuses, and load the heat treatment process curve on the HMI. Workpiece Loading: Use an overhead crane to securely place the workpieces onto the CrMnN heat-resistant hearth plates on the bogie within the effective dimensions. Bogie Infeed & Sealing: Drive the bogie smoothly into the furnace cavity, lower the door via the electric hoist, and lock the self-weight clamping mechanism for a tight seal. Thermal Processing: Start the heating program after sealing is confirmed. The system automatically regulates the thermal curve and holds temperature across zones. Cooling & Extraction: After the cycle completes, cool down as specified. Raise the furnace door once safe, drive the bogie outward, and lift off the workpieces for the next batch.

I. Equipment Overview & Functional Description This Plate-Fin Heat Exchanger Core Assembly Machine (Model: Core Assembly Machine 1200) is specifically engineered for the manual stacking and high-efficiency structural assembly of heat exchanger cores. During workshop operation, the stacked core is compressed vertically under a heavy load by two top-mounted pneumatic-hydraulic booster cylinders. This setup delivers a powerful clamping force ranging from 0 to 5 Tons (5T) that is continuously adjustable without steps, while the horizontal span of both cylinders can be modified laterally to match various core lengths. The overall external dimensions of the machine are approximately 2500 (L) $times$ 700 (W) $times$ 2600 (H) mm. Its compact and heavy-duty structural frame is optimized to support and match a targeted effective core size of $Phi1000 times 1000 times 160text{ mm}$, demonstrating premium operational adaptiveness. Through comprehensive automated pneumatic-hydraulic fastening, the system guarantees rigid geometric accuracy for the finalized plate-fin heat exchanger. The finished product verticality is tightly controlled within $pm0.6text{ mm}$; furthermore, when the core profile fits within $le 1200 times 1100text{ mm}$, the diagonal tolerance requirement is strictly locked under $< 2text{ mm}$, effectively eradicating potential brazing faults caused by misalignment. Once compressed and squared, operators can seamlessly install tension tie rods or utilize a strapping machine to wrap and secure steel bands. The pressure is then released, and the mechanical sliding table moves the completed workpiece outward by approximately 260 mm for easy crane lifting and extraction. The entire sequencing loop is conveniently handled via push-buttons, which minimizes the cycle time per batch while providing complete operational safety when handling heavy workloads. II. Flexible Processing Range & Core Technical Parameters To accommodate multi-specification customization for varied heat exchanger cores, the mechanical structures and drive strokes are engineered with large adjustable parameters. The machine features the following flexible assembly capacities: Effective Core Length Adjustable Range: Supports a wide spectrum from 300 to 1200 mm, easily accommodating the length positioning of small, medium, and large plate-fin heat exchangers. Effective Core Height Adjustable Range: Covers a vertical range from 0 to 1100 mm, where the self-adaptive vertical stroke provides ample working clearance for dense, multi-layered fin configurations. Effective Core Thickness Adjustable Range: Accommodates thicknesses from 30 to 200 mm, ensuring both slim cooling modules and deep industrial-grade core units are precisely centered and firmly clamped. III. Equipment Power Supply & Utility Requirements To ensure the assembly machine achieves long-term, uninterrupted, and stable operation under demanding manufacturing environments, all control blocks and pneumatic components are chosen based on severe workshop standards: Operational Cycle: All structural elements and power units are rated under heavy-duty deterioration constraints, fully satisfying continuous industrial 24/7 operation profiles. Operating Power Supply: Standard configuration runs on single-phase AC 220V, 50Hz (allowing smooth operational thresholds within voltage fluctuations of $pm10%$). Ambient Temperature Range: All electrical controls and sealing compounds exhibit high environmental durability, supporting regular line production from $-10^{circ}text{C}$ to $70^{circ}text{C}$. Pneumatic Supply Line: The client must provide a reliable workshop compressed air feed maintaining a gas source pressure of 0.4–0.7 MPa with a rated flow volume of at least 30 L/min. IV. Core Equipment Configurations & Hardware Architecture 1. Drive & Clamping Mechanism Design Fixture Power Motor: Driven by a high-torque stepper motor system, ensuring stable starting torque along with precise mechanical travel limit constraints. Movement Travel Speed: The horizontal movement velocity of the clamping fixture is fully adjustable by the operator from 0 to 30 meters per minute, balancing transit efficiency with alignment safety. Pressure Compressing Block: Equipped with 2 top-mounted heavy-duty pneumatic-hydraulic booster cylinders. Compared to pure pneumatic units, they provide superior pressure stability, and they remain much cleaner and oil-free compared to conventional hydraulic stations. Sliding Ejection Platform: Upon finishing the core strapping cycle, the mechanical sliding table extends outward by approximately 260 mm, freeing the workpiece entirely from the upper structure and allowing unhindered overhead crane access. 2. Critical Pneumatic & Electrical Spare Parts Solenoid Directional Valve: Industrial-grade Model 4V-310C-10 (1 Set), offering quick response times and low internal leakage. Intermediate Safety Relay: Renowned brand Model RXM2AB2BD DC24V (1 Set), securing a long lifecycle for control logic responses. V. On-Site Production Operational Process Flow System Initialization: Power on the central electrical switchboard, open the main compressed air valve, and adjust the system to the designated working pressure required by the product recipe. Dimension Setup: Calibrate and adjust the mechanical positioning of the side clamping plates to mirror the footprint of the incoming core batch. Manual Stacking Sequence: Lay down the bottom tooling fixture plate, then layer the cover plates, bar seals, and cooling fins sequentially until the core reaches its stacked target height. Alignment Clamping: Once stacking is complete, center and place the upper tooling fixture plate directly on top of the stacked core assembly. Pre-Pressing & Squaring: Actuate the upper and lower pre-press buttons to compress the stack vertically. Stop to manually adjust and square up both side faces of the core to guarantee a neat stack. Final Compressive Lock: Once squaring is verified, trigger the primary pressure button to lock the core tightly at its fully designated clamping load (0-5T). Secure the core permanently using the pull-rod fixture method or thread steel bands using an integrated strapping machine. Ejection & Cycle Reset: Release the pneumatic-hydraulic pressure, actuate the sliding platform to roll the completed core out of the workstation for crane removal, reset the mechanisms, and prepare for the next assembly run.

I. Wawasan Industri: Tuntutan Ketat untuk Keseragaman Suhu dan Transfer Otomatis dalam Pengerasan Shell Tugas Berat Dalam rantai manufaktur komponen mekanik berkekuatan tinggi dan sektor struktur berat untuk industri pertahanan nasional (seperti benda kerja baja berat dengan konfigurasi 155mm), optimalisasi sifat mekanik komprehensif—mencapai struktur mikro sorbit ideal yang memadukan kekuatan tarik tinggi dengan ketangguhan impak premium—memerlukan quenching yang ketat dan tempering suhu tinggi (Toughening/Sorbite treatment). Karena berat satuan yang besar dan kepadatan penumpukan yang tinggi dari profil ini (dengan kapasitas batch mencapai 6 ton), pemrosesan termal menghadapi dua hambatan teknis yang penting: Gradien Termal Ekstrim di Seluruh Zona: Selama tahap quenching suhu tinggi $950^{circ}text{C}$ dan tempering $650^{circ}text{C}$, perbedaan suhu yang tidak stabil di dalam zona kerja akan menyebabkan transformasi mikrostruktur yang tidak seragam, yang secara langsung merusak toleransi kekerasan dan dampak ketahanan. Kecepatan Transfer dan Bahaya Operasional: Durasi perpindahan dari saat pintu tungku dibuka hingga beban kerja 6 ton terendam seluruhnya ke dalam media pendinginan harus diminimalkan. Mengandalkan pengangkatan derek manual tradisional untuk komponen yang berat dan bercahaya tidak mencapai "jendela emas" sempit yang disyaratkan dan menimbulkan bahaya keselamatan radiasi termal yang besar bagi operator bengkel. Lini Produksi Perlakuan Panas Sepenuhnya Otomatis Tipe Forklift 3D WONDERY mewakili solusi definitif terhadap tantangan penanganan berkelanjutan batch bertonase tinggi ini. Beralih dari sabuk jaring standar atau jalur balok berjalan yang dibatasi oleh kapasitas berat, sistem ini menggunakan tata letak cluster fleksibel yang terdiri dari: 1 unit Forklift Cerdas 3D + 1 unit Tungku Pendinginan Serat Penuh + 2 unit Tungku Tempering Serat Penuh + 1 unit Tangki Pendinginan Miring Pneumatik + Stasiun Bongkar/Muat Tetap. Dengan menggunakan rangka material paduan tahan panas tugas berat, sistem ini menerapkan perutean material yang sepenuhnya otomatis, tanpa awak, dan "dikontrol dengan cerdas dengan satu tombol" di beberapa instalasi tungku dan stasiun pendingin media cair. Merujuk pada standar teknik yang dijabarkan dalam dokumen "Lini Produksi Perlakuan Panas Otomatis Kerang 155mm.docx", WONDERY merancang dan berhasil melaksanakan fasilitas perlakuan panas cerdas lengkap yang menampilkan peringkat gabungan sebesar $450teks{ kW}$ (Model: WDL260630UKR). II. Solusi Teknis dan Arsitektur Proses Full-Line 1. Penjelasan Terperinci tentang Unit Peralatan Inti Tungku Pendingin Kotak Serat Penuh (1 Set): Memiliki volume ruang efektif berukuran 1,6m Kedalaman $kali$ 1,7m Lebar $kali$ 1,2m Tinggi, dengan kapasitas pemuatan batch terukur sebesar $6teks{ ton}$. Arsitektur lapisan seluruhnya terdiri dari modul blok serat keramik tahan api aluminium silikat dengan kemurnian tinggi yang ditambatkan oleh sambungan struktural baja tahan karat, berhasil menghilangkan hubungan arus pendek termal dan kehilangan penyerapan panas yang ditemukan pada lapisan batu bata. Elemen pemanas menggunakan pita tahan suhu tinggi 0Cr27Al7Mo2 premium yang digantung dengan aman melalui penyangga keramik frekuensi tinggi di kedua dinding samping dan dinding belakang. Konfigurasi ini dibagi menjadi 3 zona kontrol suhu independen dengan nilai gabungan sebesar $180teks{ kW}$. Tungku Tempering Kotak Serat Penuh Penyiapan Ganda (2 Set): Karena waktu penahanan tempering secara tradisional lebih lama daripada durasi pemanasan quenching dalam siklus perlakuan panas sorbit standar, WONDERY mengonfigurasi 2 unit dimensi ruang yang cocok ($1.6times1.7times1.2text{ m}$). Tungku ini memiliki nilai operasi maksimum sebesar $650^{circ}text{C}$ dengan distribusi daya sebesar $120text{ kW}$ per unit (total $240text{ kW}$). Untuk memastikan distribusi termal konveksi yang cepat selama pemrosesan suhu rendah, atap setiap tungku temper dilengkapi kipas sirkulasi sentrifugal sumbu panjang yang dihubungkan dengan cangkang deflektor udara internal baja tahan karat SUS304 setebal $3text{ mm}$, menjaga keseragaman suhu tungku yang ketat sebesar $le pm5^{circ}text{C}$. Forklift Material Bermotor 3D Cerdas (1 Set Kendaraan Tanpa Jejak): Beroperasi sebagai mesin transit mekanis sentral di pabrik, forklift otomatis ini dilengkapi rangka las baja struktural tugas berat yang mampu melakukan transit maju/mundur, perpindahan lateral kiri/kanan, pengangkatan ke atas/bawah, dan manipulasi garpu 3D. Kapasitas muatan operasional yang aman dinilai sebesar $ge 6000text{ kg}$. Dipandu oleh encoder jarak fotolistrik yang tepat dan posisi batas lintasan, perpindahannya mulus dengan toleransi penyelarasan dalam $pm2text{ mm}$. Tangki Pendinginan Terkendali Kemiringan Pneumatik (1 Set): Dirancang dengan retensi volumetrik besar, tangki ini menampung 2 unit agitator fluida aliran aksial senilai $1,5text{ kW}$ dan jaringan pompa penukar panas sirkulasi volume tinggi senilai $22text{ kW}$. Ini fitur platform miring pneumatik terintegrasi di dalam tangki. Setelah forklift 3D memasukkan keranjang material ke dudukannya, sistem secara otomatis memicu aliran medium. Total waktu transit mulai dari pembukaan pintu tungku quenching, ekstraksi forklift, hingga perendaman media penuh dioptimalkan dalam $le 45text{ detik}$, mengunci struktur martensit lewat jenuh yang diinginkan dengan aman. 2. Schneider IPC + Siemens S7-1200 Komando Kontrol Pusat Digital Infrastruktur Jaringan Terdistribusi: Eksekusi logika tingkat rendah di seluruh lini bergantung pada unit pemrosesan PLC Siemens S7-1200 yang terpusat. Tungku, forklift otomatis, dan mekanisme pendinginan berkomunikasi secara terus menerus melalui fieldbus Ethernet industri (Profinet) yang terhubung langsung kembali ke konsol kontrol utama. Sentralisasi Industrial Personal Computer (IPC): Stasiun kontrol pusat menampung Industrial Personal Computer (IPC) tugas berat Schneider (atau merek papan atas yang setara) yang terintegrasi dengan perangkat lunak kontrol pengawasan dan umpan pemantauan CCTV real-time. Operator dapat menerapkan profil resep termal multisaluran yang kompleks dari ruang kontrol yang aman. Sistem ini menampilkan, melacak, mencatat, dan mengekspor riwayat pemanasan suhu penuh waktu, menghasilkan spreadsheet Excel secara otomatis yang sesuai dengan standar pertahanan global dan ketertelusuran industri yang ketat. Manajemen Daya & Resolusi Kontrol yang Presisi: Kontrol suhu bergantung pada pengontrol program PID digital cerdas layar besar yang bekerja melalui regulator daya thyristor (SCR) tiga fase tugas berat yang beroperasi dalam profil pemicu zero-crossing. Hal ini memastikan ketepatan kontrol sebesar $pm1^{circ}text{C}$ dan sepenuhnya mencegah lonjakan daya listrik yang tiba-tiba memengaruhi jaringan listrik pembangkit lokal. Jaringan & Perlindungan Keselamatan Siklus Hidup Penuh: Semua pemutus sirkuit, kontaktor, dan switchgear tegangan rendah dipilih dari merek industri premium seperti CHINT atau DELIXI, sedangkan integrasi penggerak forklift menggunakan inverter VFD Delta atau ABB berkinerja tinggi. Logika kontrolnya menerapkan loop interlocking multi-arah failsafe yang ketat yang mengelola status pintu tungku, ekstensi fork forklift, deteksi kedekatan bingkai, dan agitasi cairan, serta jaringan alarm kegagalan daya otomatis. Kotak sambungan operator mematuhi peringkat perlindungan IP55. AKU AKU AKU. Parameter Komersial dan Spesifikasi Pengiriman Turnkey Cakupan teknik lengkap dari pabrik pengolahan panas cangkang 155mm otomatis berkelanjutan ini ditawarkan dengan total penilaian EXW sebesar $163,600.00 USD: (Rincian: Forklift Bahan Berat Otomatis 3D: $62,100.00 USD; Tungku Pendinginan Kotak 6 Ton: $28,700.00 USD; Dua Set Tungku Tempering Kotak 6 Ton: $60,800.00 USD; Kontrol Terpusat IPC & Sistem CCTV Digital: $12,000.00 USD) Semua struktur utama mendukung pembongkaran modular untuk memfasilitasi pengisian peti kemas standar untuk transportasi laut internasional. Didukung oleh garansi internasional komprehensif selama 15 bulan, waktu tunggu 90 hari kerja yang efisien sejak tanda terima uang muka, dan paket lengkap skema berbahasa Inggris, gambar pondasi, dan panduan pemasangan teknis, WONDERY menjamin solusi termal presisi untuk komponen struktural tugas berat di seluruh dunia.