A wind-fog quenching device

Abstract

This utility model relates to the technical field of metal heat treatment equipment, and discloses an air-cooling and mist quenching device, including a main frame, a first air-cooling group and a first water-cooling group disposed at the top of the main frame, and a second air-cooling group and a second water-cooling group disposed at the bottom of the main frame; the air outlet of the first air-cooling group and the water outlet of the second water-cooling group are both arranged downwards, and the air outlet of the second air-cooling group and the water outlet of the second water-cooling group are both arranged upwards, and the air outlet angle of the second air-cooling group is adjustable. Because the air outlet angle of the second air-cooling group is adjustable, the airflow direction and speed within the air duct can be changed, ensuring uniform airflow distribution and avoiding insufficient or excessive cooling in certain areas. When the angle is adjusted to a suitable position, the high-speed airflow can break through the vapor film, allowing the cooling medium (water mist and air) to directly contact the workpiece surface, thereby improving heat transfer efficiency.

Description

Technical Field

[0001] This utility model relates to the technical field of metal heat treatment equipment, specifically to an air-fog quenching device, which is suitable for the rapid cooling and quenching process of complex workpieces such as high-chromium cast iron and martensitic wear-resistant steel in the casting and forging industries, especially for the quenching needs of long plate types (casting hammer plates, gyratory breakers), rod types and irregularly shaped workpieces (aluminum profiles). Background Technology

[0002] Quenching is a heat treatment process that involves heating metal to above its critical temperature, holding it at that temperature for a certain time, and then cooling it at a rate greater than the critical cooling rate to obtain a non-equilibrium microstructure dominated by martensite. This process can improve the hardness, strength, wear resistance, and corrosion resistance of metals.

[0003] The shortcomings of traditional quenching technology 1. Single-medium cooling: Pure water cooling: The excessively rapid cooling rate leads to workpiece cracking (residual stress > 300MPa), with a quenching crack rate as high as 18% for high-chromium cast iron; Pure air cooling: The cooling rate is insufficient (≤50℃ / s) and cannot meet the requirements of high-hardness materials (such as martensitic steel with hardness <HRC55). Oil cooling: produces oil mist pollution (PM2.5 concentration > 500 μg / m³) and is prone to causing fires (flash point ≤ 180℃). It is also difficult to apply to some materials that are prone to cracking.

[0004] 2. Existing hybrid cooling technologies are inadequate. Vapor film effect: When water mist comes into contact with workpieces at temperatures above 600°C, a vapor film forms, reducing heat transfer efficiency by 40%-60%. Poor cooling uniformity: The surface temperature difference of long plate-shaped workpieces (2m×0.5m) is >80℃ / cm², resulting in deformation >2mm / m; Structural rigidity defects: The deflection of the circular duct (Φ200mm) is greater than 5mm at a wind speed of 8m / s, and the welding and fixing of the guide plate results in maintenance time of ≥2h. Utility Model Content

[0005] In order to solve the problems existing in the prior art, the purpose of this utility model is to provide a wind-fog quenching device.

[0006] The present invention provides a wind-cooling and fog-quenching device, comprising a main frame, a first air-cooling group and a first water-cooling group disposed at the top of the main frame, and a second air-cooling group and a second water-cooling group disposed at the bottom of the main frame. The air outlet of the first air-cooled unit and the water outlet of the second water-cooled unit are both set downwards, while the air outlet of the second air-cooled unit and the water outlet of the second water-cooled unit are both set upwards. The air outlet angle of the second air-cooled unit is adjustable.

[0007] Preferably, the second air-cooling unit includes a plurality of second fan mechanisms arrayed at the bottom of the main frame. The second fan mechanism includes a second fan, a rectangular air duct, a plurality of guide plates, and an angle adjustment mechanism. The air outlet of the second fan is connected to one end of the rectangular air duct, and air is blown out from the top of the rectangular air duct. The plurality of guide plates are spaced apart in the rectangular air duct and can rotate relative to the rectangular air duct. The angle adjustment mechanism is disposed on the rectangular air duct and is drivenly connected to the plurality of guide plates.

[0008] Preferably, the angle adjustment mechanism includes a drive unit, a transmission screw, and a plurality of transmission gears disposed on the outside of the rectangular air duct. The drive unit is connected to the transmission screw, and the plurality of transmission gears are all meshed with the transmission screw. The plurality of transmission gears are disposed opposite to the plurality of guide plates, and when the corresponding transmission gear rotates, it drives the corresponding guide plate to rotate.

[0009] Preferably, each of the guide plates has a plurality of longitudinal guide grooves on its side.

[0010] Preferably, the first air-cooled group includes a plurality of first fans arranged in an array on the top of the main frame, with the air outlet of each first fan facing downward.

[0011] Preferably, the first water-cooling assembly includes a first water-cooling pipe, a second water-cooling pipe, a plurality of first water-cooling nozzles with built-in solenoid valves, and a plurality of second water-cooling nozzles with built-in solenoid valves disposed on the top of the main frame. The first water-cooling pipe and the second water-cooling pipe are arranged side by side. An array of the plurality of first water-cooling nozzles is disposed at the bottom of the first water-cooling pipe, and an array of the plurality of second water-cooling nozzles is disposed at the bottom of the second water-cooling pipe. The first water-cooling nozzles are solid conical nozzles, and the second water-cooling nozzles are wide-angle fan-shaped nozzles.

[0012] Preferably, the second water-cooling assembly includes a third water-cooling pipe and a fourth water-cooling pipe disposed at the bottom of the main frame, a plurality of third water-cooling nozzles with built-in solenoid valves and a plurality of fourth water-cooling nozzles with built-in solenoid valves. The third water-cooling pipe and the fourth water-cooling pipe are arranged side by side. An array of the plurality of third water-cooling nozzles is disposed at the top of the third water-cooling pipe, and an array of the plurality of fourth water-cooling nozzles is disposed at the top of the fourth water-cooling pipe. The third water-cooling nozzle is a solid conical nozzle, and the fourth water-cooling nozzle is a wide-angle fan-shaped nozzle.

[0013] Preferably, it also includes multiple temperature sensors arrayed at the top and bottom of the main frame.

[0014] Preferably, wind speed sensors are installed at the air outlets of both the first and second air-cooling units.

[0015] Preferably, it also includes a PLC controller, which is electrically connected to the first air-cooled group, the first water-cooled group, the second air-cooled group, the second water-cooled group, and the temperature sensor.

[0016] The advantages of the air-cooling device described in this utility model are that, since the outlet angle of the second air-cooling group is adjustable, the airflow direction and speed in the air duct can be changed, ensuring uniform airflow distribution and avoiding local insufficient or excessive cooling. When the angle is adjusted to a suitable position, the high-speed airflow can break through the vapor film, allowing the cooling medium (water mist and wind) to directly contact the workpiece surface, thereby improving the heat transfer efficiency. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structure of the air-fog quenching device described in this utility model; Figure 2 This is a schematic diagram of the second fan mechanism of the wind-mist quenching device described in this utility model.

[0018] Explanation of reference numerals in the attached figures: 1 Main frame, 2 First air-cooling group, 3 First water-cooling group, 31 First water-cooling pipe, 32 Second water-cooling pipe, 33 First water-cooling nozzle, 34 Second water-cooling nozzle, 4 Second air-cooling group, 41 Second fan, 42 Rectangular air duct, 43 Guide plate, 431 Guide groove, 44 Angle adjustment mechanism, 441 Drive unit, 442 Transmission screw, 443 Transmission gear, 5 Second water-cooling group, 51 Third water-cooling pipe, 52 Fourth water-cooling pipe, 53 Third water-cooling nozzle, 54 Fourth water-cooling nozzle, 6 Temperature sensor. Detailed Implementation

[0019] like Figures 1-2 As shown, this embodiment discloses a wind-cooling and mist-quenching device, including a main frame 1, a first air-cooling group 2 and a first water-cooling group 3 disposed on the top of the main frame 1, and a second air-cooling group 4 and a second water-cooling group 5 disposed at the bottom of the main frame 1. The air outlet of the first air-cooling group 2 and the water outlet of the second water-cooling group 5 are both arranged downwards, while the air outlet of the second air-cooling group 4 and the water outlet of the second water-cooling group 5 are both arranged upwards. The air outlet angle of the second air-cooling group 4 is adjustable.

[0020] The main frame 1 is a rectangular frame assembled from multiple longitudinal and transverse beams. A shelf is provided at the bottom inside the rectangular frame for placing workpieces. During quenching, the workpiece is placed on the shelf, and then the first air-cooling group 2, the first water-cooling group 3, the second air-cooling group 4, and the second water-cooling group 5 can be activated to perform the quenching operation on the workpiece. Since the air outlet angle of the second air-cooling group 4 can be adjusted, the airflow direction and speed in the air duct can be changed to ensure uniform airflow distribution and avoid local insufficient or overcooling. When the angle is adjusted to a suitable position, the high-speed airflow can break through the vapor film, allowing the cooling medium (water mist and air) to directly contact the workpiece surface, thereby improving the heat transfer efficiency.

[0021] Please refer to Figure 2 The second air-cooled unit 4 includes multiple second fan mechanisms arrayed at the bottom of the main frame 1. Each second fan mechanism includes a second fan 41, a rectangular air duct 42, multiple guide vanes 43, and an angle adjustment mechanism 44. The air outlet of the second fan 41 is connected to one end of the rectangular air duct 42, and air is blown out from the top of the rectangular air duct 42. The multiple guide vanes 43 are spaced apart within the rectangular air duct 42 and can rotate relative to the rectangular air duct 42. The angle adjustment mechanism 44 is disposed on the rectangular air duct 42 and is connected to the multiple guide vanes 43 in a transmission connection. In this embodiment, the rectangular air duct 42 is welded from Q345B steel plate with a wall thickness of 8mm. A rectangular air duct has the following advantages compared to a circular air duct: Bending strength: The moment of inertia of the rectangular air duct 42 is 2.3 times that of the equivalent circular section, making it more suitable for long spans and heavy load conditions; Maintainability: The planar structure facilitates the integration of the air deflector plate 43; Airflow controllability: The guide vane is dynamically adjusted at a 43° angle to optimize airflow distribution, improving cooling uniformity to ≤5℃ / cm².

[0022] This embodiment also conducted mechanical property tests on rectangular and circular air ducts, and the test results are shown in the table below:

[0023] Therefore, it is evident that rectangular air ducts have significant advantages in terms of strength, maintainability, and airflow control in industrial settings such as quenching equipment, making them a better choice.

[0024] Specifically, the angle adjustment mechanism 44 includes a drive unit 441, a transmission screw 442, and a plurality of transmission gears 443 disposed on the outside of the rectangular air duct 42. The drive unit 441 is connected to the transmission screw 442 in a transmission manner. The plurality of transmission gears 443 are all meshed with the transmission screw 442. The plurality of transmission gears 443 are disposed opposite to the plurality of guide plates 43. When the corresponding transmission gear 443 rotates, it drives the corresponding guide plate 43 to rotate. In this embodiment, each second fan mechanism is provided with three guide plates 43 and three corresponding transmission gears 443. The two ends of the guide plates 43 are connected to the sidewalls of the rectangular air duct 42 via shafts and bearings. One end of the shaft extends outward from the rectangular air duct 42 and connects to the transmission gear 443. When the drive unit 441 starts, it drives the transmission screw 442 to rotate, which in turn drives the transmission gear 443 to rotate. The transmission gear 443 drives the guide plates 43 to rotate, thereby adjusting the air outlet angle. The angle adjustment range of the guide plates 43 is 30°-90°, with a response time ≤0.5s and a positioning accuracy of ±0.1°. In this embodiment, the drive unit 441 can be a combination of a servo motor (400W, rated torque 1.27N·m) and a harmonic reducer (speed ratio 1:50). Furthermore, each guide plate 43 has several longitudinal guide grooves 431 on its side. The depth of the guide grooves 431 is 1mm, and the spacing is 10mm, reducing the risk of airflow separation.

[0025] In this embodiment, the first air-cooled group 2 includes multiple first fans arrayed on the top of the main frame 1, with the air outlet of each first fan facing downwards. The first water-cooled group 3 includes a first water-cooled pipe 31, a second water-cooled pipe 32, multiple first water-cooled nozzles 33 with built-in solenoid valves, and multiple second water-cooled nozzles 34 with built-in solenoid valves, all located on the top of the main frame 1. The first water-cooled pipe 31 and the second water-cooled pipe 32 are arranged side by side. Multiple first water-cooled nozzles 33 are arrayed at the bottom of the first water-cooled pipe 31, and multiple second water-cooled nozzles 34 are arrayed at the bottom of the second water-cooled pipe 32. The first water-cooled nozzles 33 are solid conical nozzles, and the second water-cooled nozzles 34 are wide-angle fan-shaped nozzles. Cooling water is pumped into each pipe by a water pump. There are nine first water-cooled nozzles 33 and nine second water-cooled nozzles 34. Three of each type are arranged sequentially from left to right on the support at the top of the main frame 1. There are also nine first fans, arranged in the same way as the nozzles, and they do not interfere with each other.

[0026] Preferably, the second water-cooling group 5 includes a third water-cooling pipe 51, a fourth water-cooling pipe 52, a plurality of third water-cooling nozzles 53 with built-in solenoid valves, and a plurality of fourth water-cooling nozzles 54 with built-in solenoid valves, all disposed at the bottom of the main frame 1. The third water-cooling pipe 51 and the fourth water-cooling pipe 52 are arranged side by side. The plurality of third water-cooling nozzles 53 are arranged in an array on the top of the third water-cooling pipe 51, and the plurality of fourth water-cooling nozzles 54 are arranged in an array on the top of the fourth water-cooling pipe 52. The third water-cooling nozzles 53 are solid conical nozzles, and the fourth water-cooling nozzles 54 are wide-angle fan-shaped nozzles. The specific arrangement is the same as that of the first water-cooling group 3.

[0027] Preferably, the system also includes multiple temperature sensors 6 arrayed at the top and bottom of the main frame 1. Eighteen temperature sensors 6 are arranged, with a range of 200-1200℃ and an accuracy of ±1%, at the top and bottom of the main frame 1, similar to the arrangement of the water-cooling unit. This high-density temperature measurement layout can capture real-time temperature changes on the workpiece surface. By monitoring the temperature difference between the upper and lower parts, the system can quickly identify temperature non-uniformity. When the temperature difference between the upper and lower parts is ≥20℃, the fan start-stop interval (30-90s) is adjusted, and the frequency conversion parameters are adjusted in real time. Wind speed sensors are installed at the air outlets of both the first air-cooling unit 2 and the second air-cooling unit 4.

[0028] Preferably, the system also includes a PLC controller, which is electrically connected to the first air-cooling group 2, the first water-cooling group 3, the second air-cooling group 4, the second water-cooling group 5, and the temperature sensor 6. Specifically, the PLC controller is a Siemens S7-1200 model with a built-in fuzzy PID algorithm, enabling variable frequency control of the fan (15-50Hz, corresponding to a speed of 900-1450 r / min), closed-loop regulation of the water pump pressure (dynamic adjustment of water pressure within the range of 0.1-0.6MPa to ensure that the cooling medium (water mist) can quickly cover the workpiece surface), and dynamic matching of the guide vane angle with the temperature gradient (ΔT / Δt). When the temperature difference between the upper and lower parts is ≥20℃, the PLC will automatically adjust the guide vane angle and the fan start-stop interval to further optimize the cooling effect. The angle adjustment of the guide vane 43 works in conjunction with the temperature feedback control system (such as the temperature sensor and the PLC fuzzy PID algorithm) to dynamically adjust the guide vane angle according to the temperature change of the workpiece surface, ensuring the uniformity and efficiency of the cooling process.

[0029] This embodiment includes a strong cooling mode and a weak cooling mode. In the strong cooling mode, both sets of nozzles of the first water cooling group 3 and the second water cooling group 5 are turned on. In the weak cooling mode, only the wide-angle fan nozzle is turned on.

[0030] This embodiment takes the quenching process of a cast hammer plate (made of Cr28) as an example: 1. Initial parameters: v. Workpiece dimensions: 1800×320×110mm, initial temperature 1050℃.

[0031] v Target hardness: HRC 60-64, allowable deformation ≤1mm / m.

[0032] 2. Strong cooling phase (>500℃): v Initial air cooling.

[0033] The vPLC detected a surface temperature of 700℃, activated all solid conical nozzles (covering a diameter of 800mm) and wide-angle fan nozzles (covering an angle of 90°), set the water pressure to 0.6MPa, and adjusted the guide plate to 75°.

[0034] The upper and lower fan units operate at full speed (1450 r / min), with an air velocity of 18 m / s and a cooling rate of 180℃ / min. Under high pressure, high air velocity, and large angle conditions, the surface of the workpiece can be cooled rapidly while simultaneously breaking down the vapor film.

[0035] 3. Weak cooling stage (400℃): v Switch to wide-angle fan nozzle, water pressure 0.2MPa, adjust the guide vane angle from 43° to 45°, and reduce the speed of the upper and lower fan units to 1000r / min.

[0036] When the system detects a local temperature difference greater than 15°C, the PLC automatically shortens the start-stop interval of the upper fan unit to 45 seconds. This prevents overcooling and maintains temperature uniformity.

[0037] The dual-mode spray system (solid cone nozzle group and wide-angle fan nozzle group) combined with the 43-degree angle adjustment of the guide plate enables precise control of the strong cooling and weak cooling stages.

[0038] 4. Measured results: v Surface temperature difference: 3.8℃ / cm² (longitudinal), 2.5℃ / cm² (transverse).

[0039] v Hardness uniformity: HB 62±1.5.

[0040] Deformation amount: 0.7mm / m, which is 65% lower than that of traditional processes.

[0041] In summary, the second air-cooling group 4 of the air-cooling device of this utility model has an adjustable air outlet angle, which can change the airflow direction and speed in the air duct, ensuring uniform airflow distribution and avoiding local insufficient or excessive cooling. When the angle is adjusted to a suitable position, the high-speed airflow can break through the vapor film, allowing the cooling medium (water mist and wind) to directly contact the workpiece surface, thereby improving the heat transfer efficiency.

[0042] In the description of this utility model, it should be understood that the orientation or positional relationship indicated by directional terms such as "front, back, up, down, left, right", "horizontal, vertical, horizontal" and "top, bottom" is usually based on the orientation or positional relationship shown in the accompanying drawings. It is only for the convenience of describing this utility model and simplifying the description. Unless otherwise stated, these directional terms do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting the scope of protection of this utility model.

[0043] For those skilled in the art, various other corresponding changes and modifications can be made based on the technical solutions and concepts described above, and all such changes and modifications should fall within the protection scope of the claims of this utility model.

Claims

1. A wind and fog quenching device, characterized in that, It includes a main frame (1), a first air-cooled group (2) and a first water-cooled group (3) disposed on the top of the main frame (1), and a second air-cooled group (4) and a second water-cooled group (5) disposed at the bottom of the main frame (1). The air outlet of the first air-cooled group (2) and the water outlet of the second water-cooled group (5) are both set downwards, and the air outlet of the second air-cooled group (4) and the water outlet of the second water-cooled group (5) are both set upwards. The air outlet angle of the second air-cooled group (4) is adjustable.

2. A wind and water quenching device according to claim 1, wherein The second air-cooled unit (4) includes multiple second fan mechanisms arrayed at the bottom of the main frame (1). The second fan mechanism includes a second fan (41), a rectangular air duct (42), multiple guide plates (43), and an angle adjustment mechanism (44). The air outlet of the second fan (41) is connected to one end of the rectangular air duct (42), and the air is blown out from the top of the rectangular air duct (42). The multiple guide plates (43) are spaced apart in the rectangular air duct (42) and can rotate relative to the rectangular air duct (42). The angle adjustment mechanism (44) is set on the rectangular air duct (42) and is connected to the multiple guide plates (43) in a transmission manner.

3. A wind and water quenching device according to claim 2, wherein The angle adjustment mechanism (44) includes a drive unit (441), a transmission screw (442), and a plurality of transmission gears (443) disposed on the outside of the rectangular air duct (42). The drive unit (441) is connected to the transmission screw (442) in a transmission manner. The plurality of transmission gears (443) are all meshed with the transmission screw (442). The plurality of transmission gears (443) are disposed opposite to the plurality of guide plates (43). When the corresponding transmission gear (443) rotates, it drives the corresponding guide plate (43) to rotate.

4. A wind and water quenching device according to claim 2, wherein Each of the aforementioned guide plates (43) has several longitudinal guide grooves (431) on its side.

5. A wind and water quenching device according to claim 1, wherein The first air-cooled group (2) includes a plurality of first fans arranged in an array on the top of the main frame (1), with the air outlet of each first fan facing downward.

6. A wind and water quenching device according to claim 1, wherein The first water-cooling assembly (3) includes a first water-cooling pipe (31) and a second water-cooling pipe (32) disposed on the top of the main frame (1), a first water-cooling nozzle (33) with multiple built-in solenoid valves and a second water-cooling nozzle (34) with multiple built-in solenoid valves. The first water-cooling pipe (31) and the second water-cooling pipe (32) are arranged side by side. An array of multiple first water-cooling nozzles (33) is disposed at the bottom of the first water-cooling pipe (31), and an array of multiple second water-cooling nozzles (34) is disposed at the bottom of the second water-cooling pipe (32). The first water-cooling nozzle (33) is a solid cone nozzle, and the second water-cooling nozzle (34) is a wide-angle fan nozzle.

7. A wind and water quenching device according to claim 1, wherein The second water-cooling assembly (5) includes a third water-cooling pipe (51), a fourth water-cooling pipe (52), a third water-cooling nozzle (53) with a built-in solenoid valve, and a fourth water-cooling nozzle (54) with a built-in solenoid valve, which are disposed at the bottom of the main frame (1). The third water-cooling pipe (51) and the fourth water-cooling pipe (52) are arranged side by side. The third water-cooling nozzle (53) is arranged in an array at the top of the third water-cooling pipe (51), and the fourth water-cooling nozzle (54) is arranged in an array at the top of the fourth water-cooling pipe (52). The third water-cooling nozzle (53) is a solid cone nozzle, and the fourth water-cooling nozzle (54) is a wide-angle fan nozzle.

8. A wind and water quenching device according to claim 1, wherein It also includes multiple temperature sensors (6) arrayed on the top and bottom of the main frame (1).

9. A wind and water quenching device according to claim 8, wherein Wind speed sensors are installed at the air outlet of the first air-cooled group (2) and the air outlet of the second air-cooled group (4).

10. A wind and water quenching device according to claim 9, wherein It also includes a PLC controller, which is electrically connected to the first air-cooled group (2), the first water-cooled group (3), the second air-cooled group (4), the second water-cooled group (5), and the temperature sensor (6).

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