Posted at 10.04.2018
This Project will involve the Monitoring and controlling of covered quench chamber. Closed quench furnace is chosen because it is only has both heating system and annealing (air conditioning) process. For other furnaces, Heating and cooling process is performed at different furnaces. Sealed quench furnaces are being used to eliminate skin decarburization of the work load floors after heat treatment and heat -chemical substance treatment process.
The monitoring and controlling of closed quench furnace is performed by using graphical software called Labview. The controlling and monitoring of furnace is performed utilizing the parameters heat range, pressure, oxygen, Raw materials level and movement turn. The furnace is also called Chamber.
Any industry will have various guidelines that are to be continuously supervised and controlled from a distant place. In the majority of the cases the utilization of manpower becomes almost impossible and therefore remote monitoring and control systems are thoroughly developed and used. Within this project closed quench furnace is checked and managed using Labview.
The goal of the job is to review and design the prototype for closed quench furnace using Labview. Sealed quench furnace is the only furnace has both cooling and heating (Annealing) process. For other furnaces, home heating and annealing process is done at different furnaces. It is used to eliminate skin decarburization of work insert surfaces after substance treatment and heat therapy process. The furnace is used to make bearings, engine parts etc. The furnace has following features
Calculation predicated on mathematical model of furnace.
Function of scientific diagrams (current profile of concentration of carbon, expected hardness profile after hardening, current state of the procedure on the diagram flat iron - carbon and iron oxidation).
Fully computerized and process repeatability.
The objective of the statement is to simulate Monitoring and managing techniques using Labview. The Strategy used in the project is monitoring and handling of covered quench furnace.
The managing and monitoring in Labview is search on internet and read them. The literature from national catalogue pays to to get information about monitoring and controlling, Labview, and furnace. The task will also need help and suggestions from supervisors. The specialized help is need which is get from countrywide tools and also be present at seminars about Labview is very useful for carrying out this project. Digital library is also useful to get information about Labview and handling of furnace.
Labview is a virtual instrumentation that predicated on the computer. By using Labview can make independent procedure executable documents.
The system will not interface to the work-in-progress system, nor might it be necessary to produce information for monitoring.
New atmosphere tempering furnace for scale-free tempering of metallic.
The new place can process batches as high as 1 ton per weight under atmosphere with closed quenching.
Components as high as 760mm can now be done vertically to reduce distortion.
Maximum component length of 1220mm can be temperature treated under manipulated atmosphere.
Computer-based order traffic monitoring, monitoring and management system introduced.
The system was designed in-house by P. H. Heat Treatment for commercial heat-treaters.
All of the above mentioned have led to greater competitiveness and improved customer support.
Controlling and monitoring is ideal for sealed quench furnace.
Temperature is bound to 1000 C
Chapter1 Reviews the advantages of covered quench furnace and Desire of task.
Chapter 2 Literature review of closed quench furnace and Labview
Chapter 3 Overview of furnace system
Chapter 4 System design, evaluation and result discussions.
Chapter 5 Advantages, Down sides and Applications of closed quench furnace.
Chapter 6 Gives the conclusions and future discussions
Furnaces are used for different temperature treating businesses depending after their temperature treat requirements
1. 150 -700 C used for nitriding, tempering, Annealing etc. . .
2. 650 -1000C- used for Hardening, Normalizing, annealing etc. . .
3. 0ver 1000C -used for hardening of hot work steel, high speed material, sinting etc. . .
Furnaces are split into Batch type and constant type. Depends upon Batch type the Quench covered furnace can be acquired as horizontal or vertical furnaces. It could use for annealing, hardening, carburizing, nitriding, nitrocarburizing etc. . . In both of these types of chamber used Heat chamber, quench chamber. The heat chamber is utilized for heating system of materials. Quench chamber is also call as Cooling chamber. The process used in this chamber is heat treatment. Heat treatment is the cooling and heating of metals to alter their physical and mechanical properties without changing their condition. Heat treatment is often associated with increasing the strength of materials, but it can be used to alter certain manufacturing properties such as improve machining, improve formability, and rebuild ductility after having a cold working operation.
SEALED QUENCH FURNACE:
Sealed quench furnace as a name defines, provides quenching under protective atmosphere. The furnace includes main heating system chamber, inlet vestibule, petrol quench tank and upper sluggish cool chamber. It is also known as Muffle or important quench furnace.
In this job defines closed quench furnace is chosen it has furnace has both cooling and heating process combined in one unit. The use of the furnace is commercial purpose.
In industry aspect the furnace is utilized for moulding of metals such as engine unit parts, equipment, etc. . .
Labview is a acronym for Lab Virtual Instrumentation Executive Workbench. It is a graphical program writing language. There is absolutely no text-based program code like other programming languages, but there is a diagrammatic view of how data flows through the program. Labview is adored tool for scientists and technicians because conventional program writing language is built and the task is achieved. Labview is created in 1986 and produced by National instruments. It really is easily learn programming language. It really is chosen because it is faster than other encoding languages. The development in Labview program is 4 times faster than other languages. The virtual device developed using Labview is, in a nutshell called a VI.
Uses of Labview:
Multiple focuses on and OS
Multiple Programming Approaches
Professional Consumer Interfaces
Saves time and money
Applications of Labview:
Acquiring Data and control signals
Automating ensure that you validation systems
Designing Embedded systems
Industrial measurements and control
Academic Teaching and Research
Civil and Structural Engineering
http://cnx. org/content/m15428/latest/ Labview
It is utilized in Airplane industry for making of aircraft engine components such as olive oil pumps, clutches, pinions, yokes, pins, manometer pistons, plane carriages etc.
It is utilized in Bearing Industry: bearing rings
It is used machine building industry drive axis, gear axles, equipment wheels, toothed wedding rings, hydraulic and pneumatic elements, bolts etc
It can be used in Automotive industry for making of gear field components and drive axles (shafts, gears etc. )
Figure 2. 1 Sealed quench furnace with control system
The stop diagram of closed quench furnace is shown in shape 2. 1. It involves Labview control system, Endo gas, Carrier gas, Air source component, and Air tube.
Figure 2. 2 Overview of sealed quench furnace
The closed quench furnace has two chambers separated by refractory lined door which may be opened to allow hot charge to be moved from temperature chamber to cool chamber. In order to determine the systems requirements, the parameter using to control the furnace are Temperatures, Pressure, Air level, Flow swap and recycleables level. The temps of the furnace is checked by thermistor. The first process is within heat chamber is the warming of materials and it is manipulated by atmosphere, LPG, Indo gas, Nitrogen. Nitrogen is used for safety purpose because use of LPG and indo gas. Indo gas and nitrogen forms carbon probable manage the raw materials found in the furnace. The control valves pressure and oxygen is supervised by sensors. Heat sensor can be used for the genuine process placed in the furnace.
The second process is in the Quench chamber is cooling down of materials. Within this controlling valves are used for managing of the furnace. The flow switch is employed for level maintenance.
In this Labview control system, it has screen and control of the furnace, with inputs of heat, oxygen, Endo gas, and pressure. The heat range of the furnace is present the predefined limit it automatically escalates the air level and reduces the gas type in the furnace. The pressure of the furnace is escalates the above the set in place limit immediately out the air from the furnace. When temperature of the furnace reduces the set limit automatically escalates the gas enters into the furnace.
Labview 8. 6 version is installed and activating on the system.
Figure 4. 1 Forward display screen of Labview
Open Empty VI for new project design. With this two glass windows are starting 1) Block diagram and
2) Front side panel
Press "CTRL+E", "CTRL+T" for both house windows shows parallel. It offers flexibility and custom made can see the both display simultaneously. It is shown in figure
Figure 4. 2 cascade home windows of Labview
In this deigning the monitoring and controlling of furnace, includes the five monitors the following screen Main display, Report display, Run screen, Setup display screen and About us display.
The main display screen has About Us, Survey, Run, Setup, Leave and login icons. The run icon interconnects to the run component. The installation icon interconnects to the set up module screen. The Statement icon interconnects to the statement screen. The about us icon interconnects to the about us screen.
Figure 4. 3 main display front panel
Figure 4. 4 Block diagram of main screen
In setup screen the configurations of furnace are outlined.
Figure 4. 5 Installation screen entrance panel
Figure 4. 6 set up screen stop diagram
Figure 4. 7 statement screen forward panel
Figure 4. 8 statement screen block diagram
Run display screen:
Figure 4. 9 run screen block diagram
About Us screen
Figure 4. 11 About us screen front panel
Figure 4. 12 About us screen block diagram
The Labview is the latest programming tool and there are not enough reference books are available.
Labview is latest design tool how to utilize this software
The developing of installation screen
Labview information is get from internet source plus some books are receiving from national collection.
Attend the workshop at national tools, Singapore for using of Labview.
1. Benefits of covered quench furnace:
Avoids manual errors
Wastage reduced and cost saving
Consistency in the event depth and surface hardness.
2. Cons of closed quench furnace:
Very fast quench
Corrosive quench tank
Fixtures and fitting
High protection need
Limitation of weight (750 / 1000 kgs)
Power usage high
Use only special gases
Repeated process not applicable
Only used hot quenching engine oil (oil cost high).
3. Top features of sealed quench furnace are shown below
Controlled atmosphere annealing
The covered quench furnace using applications are shown below
Stainless less metallic materials
Making of tools
Making of steels
Making of machine parts, etc. . . . . .
The monitoring and managing of sealed quench furnace using Labview is designed and analyzed with valid variables. The Monitoring and handling of sealed quench furnace is efficiently tested and satisfies all the goals required to function accordingly. The problems arise were experienced, it is controllable and resolved with technical direction.
The realization from the performance results are
Graphical programming is versatile and easy.
Program design can be changed easily based on the client requirements.
Overall the machine is efficient
The prototype was efficiently developed to meet its targets but it could be further improved based on hardware design.