Nitriding Potential Control via Single Mass Flow Controller
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Solution Overview
Problem
Existing surface hardening treatment methods require complex control of ammonia and ammonia decomposition gas flow rates to achieve precise nitriding potential, necessitating multiple mass flow controllers and increasing costs.
Innovation Solution
A surface hardening treatment device and method that control nitriding potential by adjusting the ammonia gas flow rate while keeping the ammonia decomposition gas flow rate constant, eliminating the need for a mass flow controller for the decomposition gas and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex control of ammonia and ammonia decomposition gas flow rates is implemented to achieve precise nitriding potential, then nitriding potential control precision is improved, but device complexity and cost increase due to requiring multiple mass flow controllers
Solution Approach 1:
The invention extracts and removes one mass flow controller from the system by recognizing that the ammonia decomposition gas flow rate can be kept constant throughout the treatment process. Only the ammonia gas flow rate needs to be dynamically controlled to adjust nitriding potential, thereby simplifying the device while maintaining control precision.
Solution Approach 2:
The invention changes the control strategy by fixing one parameter (ammonia decomposition gas flow rate) and dynamically adjusting only the other parameter (ammonia gas flow rate). This parameter change approach reduces the number of active control elements needed while maintaining the ability to precisely control nitriding potential.
2Manufacturing precision
If multiple mass flow controllers are used to control both ammonia and ammonia decomposition gas flow rates, then gas flow control precision is improved, but cost increases
Solution Approach 1:
The invention removes the unnecessary mass flow controller for ammonia decomposition gas from the system. By establishing that this gas flow rate can remain constant, the patent eliminates the associated equipment cost while preserving sufficient control precision through the remaining ammonia gas mass flow controller.
Solution Approach 2:
The invention replaces the expensive dual mass flow controller configuration with a simpler, more cost-effective single mass flow controller setup. This cost-reduction approach maintains the essential control functionality needed for precise nitriding potential adjustment.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Achieves precise control of nitriding potential with reduced equipment needs, enabling efficient and cost-effective surface hardening treatments for a wide range of nitriding conditions.
Implementation Method 1
a process in which only nitrogen is permeated and diffused into a work, in order to harden a surface of the work
Implementation Method 2
nitrogen is permeated and diffused into a work
Implementation Method 3
a mixed gas of an ammonia gas and an ammonia decomposition gas (which consists of 75% hydrogen and 25% nitrogen)
Implementation Method 4
carbon is secondarily permeated and diffused into a work together with nitrogen
Implementation Method 5
carbon is secondarily permeated and diffused into a work
Data Source
AI summary
Based on the nitriding potential in the processing furnace calculated by the in-furnace nitriding potential calculator and the target nitriding potential, the introduction amount of the ammonia gas is changed while the introduction amount of the ammonia decomposition gas is kept constant, such that the nitriding potential in the processing furnace is brought close to the target nitriding potential.