Bolt heat treatment control system

Abstract

The invention provides a bolt heat treatment control system which comprises a heat treatment mesh belt furnace and a control assembly, and the heat treatment mesh belt furnace comprises a furnace body, a conveying device arranged in the furnace body and used for conveying workpieces, a natural gas combustion device and a steam generation device. The control assembly comprises a controller, a sensor assembly arranged in the furnace body and a flow meter arranged on a water inlet pipeline of the steam generation device, and the controller adjusts the steam generation amount of the steam generation device based on the furnace interior temperature, the furnace interior humidity and the furnace interior oxygen concentration detected by the sensor assembly. Dynamic adjustment of reaction parameters is achieved through a closed-loop control system, accurate control over the temperature, humidity and oxygen concentration in the furnace is achieved, and therefore the quality of an anti-rust film layer is improved.

Description

Technical Field

[0001] This invention relates to the field of bolt processing, and more specifically, to a bolt heat treatment control system. Background Technology

[0002] As a core component of mechanical connections, bolts' rust-proof performance directly determines the assembly reliability and service life of equipment. If bolts rust during use, it can easily lead to serious quality accidents such as assembly failure and breakage. Currently, bolt heat treatment rust prevention processes are mainly divided into two categories: chemical blackening and steam blackening. Chemical blackening relies on the reaction of chemical agents with the bolt surface to generate a rust-proof film, which has problems such as high energy consumption, serious pollution, and large footprint. Steam blackening, on the other hand, is based on the oxidation reaction of iron and water vapor at high temperatures (3Fe + 4H₂O → Fe₃O₄↓ + 4H₂↑), generating a dense black Fe₃O₄ oxide film, which has the advantage of being environmentally friendly and pollution-free.

[0003] However, while existing steam blackening processes can achieve bolt blackening, they still have the following drawbacks: Existing technologies cannot achieve uniform distribution of water vapor and do not precisely control key reaction parameters such as furnace temperature, humidity, and oxygen concentration, resulting in fluctuating oxidation atmosphere, unstable Fe3O4 film formation, and significant differences in rust prevention effects.

[0004] Therefore, it is necessary to improve the existing bolt heat treatment control system. Summary of the Invention

[0005] The main objective of this application is to provide a bolt heat treatment control system that achieves dynamic adjustment of reaction parameters through a closed-loop control system, thereby enabling precise control of furnace temperature, humidity, and oxygen concentration, and thus improving the quality of the anti-rust film.

[0006] To achieve the above objectives, in a first aspect, this application provides a bolt heat treatment control system, including a heat treatment mesh belt furnace and a control component. The heat treatment mesh belt furnace includes a furnace body, a conveying device disposed within the furnace body for conveying workpieces, a natural gas combustion device, and a steam generating device. The control component includes a controller, a sensor assembly disposed within the furnace body, and a flow meter disposed on the water inlet pipe of the steam generating device. The controller adjusts the steam generation rate of the steam generating device based on the furnace temperature, furnace humidity, and furnace oxygen concentration detected by the sensor assembly.

[0007] Optionally, the water vapor generation amount = basic water vapor generation amount + water vapor generation correction amount, wherein the water vapor generation correction amount... Where K1 is the oxygen concentration correction coefficient, K2 is the temperature correction coefficient, K3 is the humidity correction coefficient, C1 is the oxygen concentration in the furnace detected by the sensor component, C2 is the optimal oxygen concentration, T1 is the furnace temperature detected by the sensor component, T2 is the optimal reaction temperature, A1 is the furnace humidity detected by the sensor component, and A2 is the optimal relative humidity.

[0008] Optionally, the controller adjusts the water intake of the steam generator based on the calculated amount of water vapor generated.

[0009] Optionally, the water inflow rate ,in K represents the gasification efficiency of the steam generator, and K4 is the temperature compensation coefficient. .

[0010] Optionally, the steam generator is equipped with a high-frequency ultrasonic activation module to process the vaporized water vapor into nano-sized water mist by ultrasonic treatment at 20-40kHz.

[0011] Optionally, the conveying device is a segmented speed-regulating mesh belt with a speed adjustment range of 0.5-2m / min.

[0012] Optionally, the conveyor belt speed for bolts of models M3-M10 is 1.5-2 m / min, and the conveyor belt speed for bolts of models M11-M30 is 0.5-1 m / min.

[0013] Optionally, the sensor assembly is an integrated temperature, humidity, and oxygen concentration sensor.

[0014] The bolt heat treatment control system provided by this invention has the following advantages compared with the prior art: it can accurately control the furnace atmosphere within the optimal range through closed-loop control, increase the density of the Fe3O4 anti-rust film by more than 20%, extend the corrosion resistance time of bolt salt spray test from 48h in the prior art to more than 72h, and automatically complete parameter acquisition, calculation and adjustment of the entire process by the PLC control system, reducing the amount of manual intervention and improving production efficiency by more than 25%. Attached Figure Description

[0015] The accompanying drawings, which form part of this application, are used to provide a further understanding of the application and to make other features, objects, and advantages of the application more apparent. The illustrative embodiments and descriptions of this application are used to explain the application and do not constitute an undue limitation of the application. In the drawings: Figure 1 This is a schematic diagram of a heat treatment mesh belt furnace. Detailed Implementation

[0016] To enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present application, and not all embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative effort should fall within the scope of protection of the present application.

[0017] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate for the embodiments of this application described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0018] In this application, the terms "upper," "lower," "left," "right," "front," "rear," "top," "bottom," "inner," "outer," "middle," "vertical," "horizontal," "lateral," and "longitudinal" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. These terms are primarily for the purpose of better describing this application and its embodiments, and are not intended to limit the indicated device, element, or component to having a specific orientation, or to be constructed and operated in a specific orientation.

[0019] Furthermore, in addition to indicating location or positional relationship, some of the aforementioned terms may also have other meanings. For example, the term "above" may also be used in some cases to indicate a certain dependency or connection relationship. Those skilled in the art can understand the specific meaning of these terms in this application based on the specific circumstances.

[0020] In addition, the term "multiple" should mean two or more.

[0021] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. This application will now be described in detail with reference to the accompanying drawings and embodiments.

[0022] like Figure 1As shown, a bolt heat treatment control system includes a heat treatment mesh belt furnace and a control component. The heat treatment mesh belt furnace includes a furnace body, a conveying device for conveying workpieces disposed within the furnace body, a natural gas combustion device, and a steam generator. The control component includes a controller, a sensor assembly disposed within the furnace body, and a flow meter disposed on the water inlet pipe of the steam generator. The controller adjusts the steam generation rate of the steam generator based on the furnace temperature, furnace humidity, and furnace oxygen concentration detected by the sensor assembly.

[0023] Specifically, the water vapor generation amount = basic water vapor generation amount + water vapor generation correction amount, where the water vapor generation correction amount... Where K1 is the oxygen concentration correction coefficient, K2 is the temperature correction coefficient, K3 is the humidity correction coefficient, C1 is the oxygen concentration in the furnace detected by the sensor component, C2 is the optimal oxygen concentration, T1 is the furnace temperature detected by the sensor component, T2 is the optimal reaction temperature, A1 is the furnace humidity detected by the sensor component, and A2 is the optimal relative humidity.

[0024] The basic steam generation rate is related to the furnace volume. For example, for a 10m³ furnace, the rate is 20L / h. The oxygen concentration correction coefficient K1 is 0.8-1.2, preferably 1.0. The temperature correction coefficient K2 is 0.3-0.5, preferably 0.4. The humidity correction coefficient K3 is 0.2-0.3, preferably 0.25. The optimal oxygen concentration C2 is usually 3%-5%, preferably 4%. The optimal reaction temperature T2 is usually 350-400℃, preferably 380℃. The optimal relative humidity inside the furnace A2 is usually 60%-70%, preferably 65%. The above formulas only use numerical values ​​for calculation and do not consider dimensions.

[0025] The controller adjusts the water intake of the steam generator based on the calculated amount of steam generated.

[0026] The water inflow ,in K represents the gasification efficiency of the steam generator, and K4 is the temperature compensation coefficient. ,in The typical value is 85%-92%, with 90% being preferred. The temperature compensation coefficient K4 is set to 0.005 / ℃. For every 1℃ decrease in temperature below 400℃, the influent flow rate increases by 0.5%, resulting in a decrease in the compensation gasification efficiency. For example, at 390℃, ΔT=-10℃, and the influent flow rate increases by 5%.

[0027] Preferably, the steam generator is equipped with a high-frequency ultrasonic activation module, which treats the vaporized water vapor into nano-sized water mist by ultrasonic treatment at 20-40kHz. Through ultrasonic activation, the reaction rate is increased by more than 30%, and a qualified Fe3O4 film layer can be generated at a low temperature of 320℃. This avoids the disadvantages of high energy consumption and high temperature causing workpiece deformation, and has the advantage of "low temperature and high efficiency".

[0028] Preferably, the conveying device is a segmented speed-regulating mesh belt with a speed adjustment range of 0.5-2m / min. Specifically, the mesh belt speed for M3-M10 bolts is 1.5-2m / min, and the mesh belt speed for M11-M30 bolts is 0.5-1m / min. For workpieces of different sizes such as bolts and nuts, the reaction time can be controlled by adjusting the mesh belt speed. By utilizing the "speed-airflow" dual adjustment mechanism, full-size adaptation from M3 micro bolts to M30 large nuts can be achieved.

[0029] The sensor assembly is an integrated temperature, humidity, and oxygen concentration sensor with a measurement range of 0-500℃, 0-100% RH, and 0-21% oxygen concentration. The integrated sensor reduces the installation volume of sensors inside the furnace.

[0030] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A bolt heat treatment control system, characterized in that, The system includes a heat treatment mesh belt furnace and a control component. The heat treatment mesh belt furnace includes a furnace body, a conveying device for conveying workpieces disposed within the furnace body, a natural gas combustion device, and a steam generating device. The control component includes a controller, a sensor assembly disposed within the furnace body, and a flow meter disposed on the water inlet pipe of the steam generating device. The controller adjusts the amount of steam generated by the steam generating device based on the furnace temperature, furnace humidity, and furnace oxygen concentration detected by the sensor assembly.

2. The bolt heat treatment control system as described in claim 1, characterized in that: The water vapor generation rate = basic water vapor generation rate + water vapor generation correction rate, where the water vapor generation correction rate is... Where K1 is the oxygen concentration correction coefficient, K2 is the temperature correction coefficient, K3 is the humidity correction coefficient, C1 is the oxygen concentration in the furnace detected by the sensor component, C2 is the optimal oxygen concentration, T1 is the furnace temperature detected by the sensor component, T2 is the optimal reaction temperature, A1 is the furnace humidity detected by the sensor component, and A2 is the optimal relative humidity.

3. The bolt heat treatment control system as described in claim 2, characterized in that: The controller adjusts the water intake of the steam generator based on the calculated amount of steam generated.

4. A bolt heat treatment control system as described in claim 3, characterized in that: The water inflow ,in K represents the gasification efficiency of the steam generator, and K4 is the temperature compensation coefficient. .

5. A bolt heat treatment control system as described in claim 1, characterized in that: The steam generator is equipped with a high-frequency ultrasonic activation module, which processes the vaporized water vapor into nano-sized water mist using 20-40kHz ultrasound.

6. A bolt heat treatment control system as described in claim 1, characterized in that: The conveying device is a segmented speed-regulating mesh belt with a speed adjustment range of 0.5-2m / min.

7. A bolt heat treatment control system as described in claim 6, characterized in that: The conveyor belt speed for bolts of models M3-M10 is 1.5-2 m / min, and the conveyor belt speed for bolts of models M11-M30 is 0.5-1 m / min.

8. A bolt heat treatment control system as described in claim 1, characterized in that: The sensor assembly is an integrated temperature, humidity, and oxygen concentration sensor.

Images