Development of deep ion nitriding process and equipment (4)

2. Development of computer-controlled ion nitriding equipment for deep nitriding of gears

The smooth implementation of the process requires advanced equipment to guarantee, but at present, most of the ion nitriding furnaces used in industrial production in China are simple in structure, low in automation, and the structure is not reasonable enough. In recent years, with the development of power electronics technology and industrial automation control technology, the technology of domestic pulse power supply has matured. Due to its series of advantages, it has been accepted by the market and has been widely used, computer controlled ion nitriding equipment. It has also been gradually developed and its functions have been improved.

This paper describes the ion nitriding equipment system designed and developed for a company's gear products (ring gear, worm and small modulus gears, etc.), which integrates the current advanced domestic configuration and is equipped with a computer control system. About the software.
In addition, the furnace auxiliary heating system is added, which is beneficial to increase the heating temperature, improve the furnace temperature uniformity, reduce the arc cleaning and heating time, especially the plasma-based ion source and the heat source. Separate control of the system helps to reduce the occurrence of arc discharges to more widely adjust and control process parameters.

The main technical parameters and configuration of the equipment are as follows: effective working area is 1600mm × 1500mm, ion heating power is 200kW, auxiliary heating power is 75kW, one with 2X-70 and 2X-30 rotary vane vacuum pumps, ion heating transformer and One auxiliary heating transformer, one power control cabinet and one PC computer. The system configuration and connection are shown in Figure 5. The main features are discussed below.

Auxiliary heating system

The auxiliary heating resistance wire is made of 8mm 0Cr25Al5 iron-chromium aluminum alloy wire vertically fixed on the heat insulation screen of the furnace. The ceramic insulation is used between the insulation screen and the heat insulation screen. The auxiliary heating line voltage is 90V, and the current output is 0~480A. A total of 30 uniform distributions in the circumferential direction, 5 sets of heaters in each group, and then parallel star connection. The heating power is regulated by a bidirectional thyristor and can be continuously given.

2. Selection of main instruments and meters

In the past, the vacuum measurement of the ion nitriding furnace mostly uses a resistance vacuum gauge. The resistance vacuum gauge is sensitive to the measured medium composition. It is calibrated according to the air medium, and can be used when the furnace is pre-vacuum, and the furnace is ventilated during the nitriding process. There will be no reference value for future readings. Therefore, we use the more advanced CPCA-100Z capacitive membrane absolute pressure transmitter to accurately measure and control the furnace pressure during the actual nitriding process.

Ordinary glass rotor flowmeters can only be manually adjusted, and automation and control cannot be achieved due to poor accuracy and stability. The D07-7B mass flowmeter selected in this system can accurately measure and control the flow without being affected by the pressure and type of the medium. A total of 4 mass flowmeters are respectively connected with nitrogen, hydrogen, ammonia and propane. Gas to meet the needs of different processes.

The vacuum butterfly valve is driven by Nucom-Z drive device. It can get 4~20mA current signal through the positioner on the power cabinet, and it can be added to the drive device. The butterfly valve opening angle can be controlled at any position from 0 to 90° instead of manual. The adjustment is made to achieve the purpose of controlling the pumping rate of the vacuum pump.

3. Computer Control System

This system adopts Mitsubishi programmable control system and PC, and is equipped with Beijing Kunlun state-of-the-art intelligent Chinese human-machine interface. The system connection is shown in Figure 6.

The software main menu includes five sub-menus, as shown in Figure 7 and Figure 8, in which the temperature setting of 10 sections and the pressure setting of 10 sections can be performed in the sub-menu of "warming and warming parameter setting". The parameters such as voltage, time, auxiliary heating power, and medium flow rate can be set. Input and store the relevant parameters of the process, and enter the operation interface to realize the fully automatic operation of the process. The temperature and pressure parameters during the process execution can be recorded in real time, and can be adjusted and printed.

This equipment is used for deep nitriding production of gears.

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