CN108106412B - 一种高效率刹车盘生产设备及应用 - Google Patents
一种高效率刹车盘生产设备及应用 Download PDFInfo
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- CN108106412B CN108106412B CN201711138474.2A CN201711138474A CN108106412B CN 108106412 B CN108106412 B CN 108106412B CN 201711138474 A CN201711138474 A CN 201711138474A CN 108106412 B CN108106412 B CN 108106412B
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- furnace
- stock column
- brake disc
- production equipment
- disc production
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 54
- 238000010438 heat treatment Methods 0.000 claims abstract description 22
- 239000000203 mixture Substances 0.000 claims abstract description 4
- 239000000463 material Substances 0.000 claims description 28
- 210000000214 Mouth Anatomy 0.000 claims description 19
- OKTJSMMVPCPJKN-UHFFFAOYSA-N carbon Chemical compound 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- 206010018987 Haemorrhage Diseases 0.000 claims description 16
- 230000000740 bleeding Effects 0.000 claims description 16
- 231100000319 bleeding Toxicity 0.000 claims description 16
- 229910052799 carbon Inorganic materials 0.000 claims description 16
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
- F27B5/00—Muffle furnaces; Retort furnaces; Other furnaces in which the charge is held completely isolated
- F27B5/04—Muffle furnaces; Retort furnaces; Other furnaces in which the charge is held completely isolated adapted for treating the charge in vacuum or special atmosphere
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
- F27B5/00—Muffle furnaces; Retort furnaces; Other furnaces in which the charge is held completely isolated
- F27B5/06—Details, accessories, or equipment peculiar to furnaces of these types
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
- F27B5/00—Muffle furnaces; Retort furnaces; Other furnaces in which the charge is held completely isolated
- F27B5/06—Details, accessories, or equipment peculiar to furnaces of these types
- F27B5/14—Arrangements of heating devices
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
- F27B5/00—Muffle furnaces; Retort furnaces; Other furnaces in which the charge is held completely isolated
- F27B5/06—Details, accessories, or equipment peculiar to furnaces of these types
- F27B5/16—Arrangements of air or gas supply devices
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
- F27B5/00—Muffle furnaces; Retort furnaces; Other furnaces in which the charge is held completely isolated
- F27B5/06—Details, accessories, or equipment peculiar to furnaces of these types
- F27B5/18—Arrangement of controlling, monitoring, alarm or like devices
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D1/00—Casings; Linings; Walls; Roofs
- F27D1/12—Casings; Linings; Walls; Roofs incorporating cooling arrangements
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D11/00—Arrangement of elements for electric heating in or on furnaces
- F27D11/02—Ohmic resistance heating
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D5/00—Supports, screens, or the like for the charge within the furnace
- F27D5/0068—Containers
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D7/00—Forming, maintaining, or circulating atmospheres in heating chambers
- F27D7/02—Supplying steam, vapour, gases, or liquids
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D7/00—Forming, maintaining, or circulating atmospheres in heating chambers
- F27D7/06—Forming or maintaining special atmospheres or vacuum within heating chambers
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
- F27B5/00—Muffle furnaces; Retort furnaces; Other furnaces in which the charge is held completely isolated
- F27B5/06—Details, accessories, or equipment peculiar to furnaces of these types
- F27B5/16—Arrangements of air or gas supply devices
- F27B2005/161—Gas inflow or outflow
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS, OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D7/00—Forming, maintaining, or circulating atmospheres in heating chambers
- F27D7/06—Forming or maintaining special atmospheres or vacuum within heating chambers
- F27D2007/066—Vacuum
Abstract
一种高效率刹车盘生产设备及应用。一种高效率刹车盘生产设备,其组成包括:炉体(1),所述的炉体(1)内的外圆设置有9根均匀分布的料柱(2),所述的炉体(1)内的中间部位设置3根中心料柱(3),所述的料柱(2)包裹在圆筒形外加热器(4)内,所述的炉体(1)的底部设置3个辅助加热器(5),所述的辅助加热器(5)作用于所述的中心料柱(3)。本发明用于生产刹车盘。
Description
技术领域
本发明涉及一种高效率刹车盘生产设备及应用。
背景技术
随着碳陶刹车盘优异的性能目前广泛用于高速列车、汽车和飞机上的刹
车材料;
主要是粉末冶金和C/C 复合材料;然而,粉末冶金刹车材料存在高温容
易粘结、摩擦性能衰退、高温强度下降显著、抗热震能力差、使用寿命短等
缺点;与传统金属及半金属刹车材料相比,C/SiC其具有密度低、强度高、摩
擦性能稳定、摩擦量制动比大、耐高温、使用寿命长等优点。因此, 刹车材
料在高速列车、汽车、飞机等领域具广阔应用前景。目前已在保时捷911、奥
迪A8L、法拉利等高档汽车上得以应用但其C/C材料生产周期长约600h及
生产成本高等问题,制约了其进一步发展及应用。
目前在国内生产C/C刹车材料的生产设备主要是以真空感应炉为主,因只有外坩埚发热国内最大直径1600mm高2000mm均温区±20℃,有效利用空间受均温区直径影响,大批量低成本生产成为行业内主要瓶颈。
发明内容
本发明的目的是提供一种提高了碳刹车盘的生产效率,降低了其生产成本,稳定生产质量,延长了使用寿命的一种高效率刹车盘生产设备及应用。
上述的目的通过以下的技术方案实现:
一种高效率刹车盘生产设备,其组成包括:炉体(1),所述的炉体(1)内的外圆设置有9根均匀分布的料柱(2),所述的炉体(1)内的中间部位设置3根中心料柱(3),所述的料柱(2)包裹在圆筒形外加热器(4)内,所述的炉体(1)的底部设置3个辅助加热器(5),所述的辅助加热器(5)作用于所述的中心料柱(3)。
所述的一种高效率刹车盘生产设备,所述的圆筒形外加热器(4)分布在所述的炉体(1)内的上部、中部、下部,所述的圆筒形外加热器(4)与所述的辅助加热器(5)均由数根石墨管沿圆周均匀分布,形成一个三角形接法鼠笼结构。
所述的一种高效率刹车盘生产设备,所述的炉体(1)的顶部设置有上炉盖(6),所述的上炉盖(6)上设置12 个料柱抽气口(7)和12个进气口(8),所述的料柱抽气口(7)与所述的料柱(2)和所述的中心料柱(3)相对应,所述的进气口(8)与所述的料柱(2)和所述的中心料柱(3)相对应,所述的进气口(8)连接压力传感器(9),所述的料柱抽气口(7)连接智能控制蝶阀(10)。
所述的一种高效率刹车盘生产设备,所述的炉体(1)的底部设置有12个料柱口(11),所述的料柱口(11)与所述的料柱抽气口(7)一一同轴对应。
所述的一种高效率刹车盘生产设备,所述的炉体(1)为立式双层夹套水冷圆筒式结构,由下炉底(12)、下筒节(13)、上筒节(14)和上炉盖(6)组成;所述的下筒节(13)与所述的上筒节(14)之间通过法兰盘(15)连接,所述的炉体(1)内径为4.2m,所述的下筒节(13)与所述的上筒节(14)均设置4 个上热电偶测温口(19),所述的法兰盘(15)之间装有O型密封圈,所述的炉体(1)包括外壳体、夹层(22)、内壳体(23),所述的夹层(22)位于所述的外壳体与所述的内壳体(23)之间。
所述的一种高效率刹车盘生产设备,所述的料柱口(11)的直径为780mm,所述的料柱口(11)对应安装料柱料台(16),所述的料柱料台(16)的中心设置一个充气气路(24),所述的充气气路(24)内充有氮气和丙烯气。
所述的一种高效率刹车盘生产设备,辅助加热器(5)连接水冷电极(17),所述的水冷电极(17)连接所述的圆筒形外加热器(4),所述的炉体(1)的底部设置有6个热电偶测温口(18)。
所述的一种高效率刹车盘生产设备,所述的下炉底(12)、所述的下筒节(13)、所述的上筒节(14)、所述的上炉盖(6)均连接碳毡保温层(20),所述的碳毡保温层(20)为软碳毡,软碳毡卷筒后固定在一个金属外框骨架(21)上,并用碳绳和碳碳螺杆连接固定。
所述的一种高效率刹车盘生产设备,所述的炉体(1)材料为Q235 碳钢材质,所述的法兰盘(15)材料为碳钢材质。
一种高效率刹车盘生产设备的应用,本高效率刹车盘生产设备用于生产刹车盘。
有益效果:
1.本发明针对现有技术的不足,提供采用立式圆筒形结构,装出料方式采用下开盖,升降式装取料;装料方式采用多料柱结构共12 个石墨料柱;加热方式采用外加热压差法,结合内辅助加热器加热;设备抽真空系统由3 套独立的真空过滤系统组成。设备设计以“人”为指导理念,突出设备操作的安全性、机械操作的可靠性和电气控制系统的精确性的一种对刹车盘材料进行渗透的设备,以提高碳刹车盘的生产效率,降低其生产成本,稳定生产质量,提高使用寿命。
2.现有的炉膛尺寸越大温度的均匀性会越差,因真空炉热量主要是以热辐射为主,当外圈发热体辐射外9个料柱后内部三个料柱无法收到发热体直接辐射,本发明采用辅助加热系统对3个中间料柱进行热辐射,达到中间料柱在加热器包围的状态下,保证炉内均温性。
3.目前国内还没有实现炉内12个料柱进出口压力可在一个炉腔内单独调控的装置,本发明在上炉盖上设置12 个料柱抽气口和12个进气口,12进气口处分别安装12个压力传感器检测进气压力,料柱抽气口处为保证每根料柱压力单独调控,在料柱抽气口处安装12个智能控制蝶阀控制每个料柱的出气速度来调整料柱内压力,12 个料柱抽气口与炉底12 个料柱口分别同轴对应。
4.本发明装载量大,控制精度高、均温性可达到±8℃以内,并可以单料柱通过调节各室进排气压力达到快速、稳定沉积降低生产成本的目的。
5.普通沉积炉生产数量与本发明产品数量,
产能对比:
表1
350刹车盘料柱数量 | 产品数量 | |
1600mm感应炉 | 9 | 585 |
本炉型 | 36 | 2340 |
沉积速率对比:
表2
350刹车盘料柱数量 | 生产时间 | |
1600mm感应炉 | 9 | 600 |
本炉型 | 36 | 400 |
单件产品成本对比(元):
表3
350刹车盘料柱数量 | 用电量,用气 | |
1600mm感应炉 | 9 | 650 |
本炉型 | 36 | 180 |
通过表1-3数据可知,由本发明生产的产品沉积速率提高30%以上单件成本降低72%生产产量提高4倍,为后期碳陶刹车盘的广泛推广提供了先天形式。
附图说明
附图1是本产品的结构示意图。
附图2是本产品的外观俯视图。
附图3是本产品的外观主视图。
附图4是本产品的炉体与圆筒形外加热器、辅助加热器的结构示意图。
具体实施方式
下面将结合本发明实施例中的附图,对本发明实施例中的技术方案进行清楚、完整地描述。
实施例1:
一种高效率刹车盘生产设备,其组成包括:炉体1,所述的炉体1内的外圆设置有9根均匀分布的料柱2,所述的炉体1内的中间部位设置3根中心料柱3,所述的料柱2包裹在圆筒形外加热器4内,所述的炉体1的底部设置3个辅助加热器5,所述的辅助加热器5作用于所述的中心料柱3。
辅助加热器共三个,布置在炉底上,目的是为了提高料柱之间的受热均匀性。
实施例2:
实施例1所述的一种高效率刹车盘生产设备,所述的圆筒形外加热器4分布在所述的炉体1内的上部、中部、下部,所述的圆筒形外加热器4与所述的辅助加热器5均由数根石墨管沿圆周均匀分布,形成一个三角形接法鼠笼结构。
实施例3:
实施例2所述的一种高效率刹车盘生产设备,所述的炉体1的顶部设置有上炉盖6,所述的上炉盖6上设置12 个料柱抽气口7和12个进气口8,所述的料柱抽气口7与所述的料柱2和所述的中心料柱3相对应,所述的进气口8与所述的料柱2和所述的中心料柱3相对应,所述的进气口8连接压力传感器9,所述的料柱抽气口7连接智能控制蝶阀10。
实施例4:
实施例3所述的一种高效率刹车盘生产设备,所述的炉体1的底部设置有12个料柱口11,所述的料柱口11与所述的料柱抽气口7一一同轴对应。
实施例5:
实施例3所述的一种高效率刹车盘生产设备,所述的炉体1为立式双层夹套水冷圆筒式结构,由下炉底12、下筒节13、上筒节14和上炉盖6组成;所述的下筒节13与所述的上筒节14之间通过法兰盘15连接,所述的炉体1内径为4.2m,所述的下筒节13与所述的上筒节14均设置4 个上热电偶测温口19,所述的法兰盘15之间装有O型密封圈,所述的炉体1包括外壳体、夹层22、内壳体23,所述的夹层22位于所述的外壳体与所述的内壳体23之间。
实施例6:
实施例4所述的一种高效率刹车盘生产设备,所述的料柱口11的直径为780mm,所述的料柱口11对应安装料柱料台16,所述的料柱料台16的中心设置一个充气气路24,所述的充气气路24内充有氮气和丙烯气。
实施例7:
实施例1所述的一种高效率刹车盘生产设备,辅助加热器5连接水冷电极17,所述的水冷电极17连接所述的圆筒形外加热器4,所述的炉体1的底部设置有6个热电偶测温口18。
实施例3:
实施例1所述的一种高效率刹车盘生产设备,所述的下炉底12、所述的下筒节13、所述的上筒节14、所述的上炉盖6均连接碳毡保温层20,所述的碳毡保温层20为软碳毡,软碳毡卷筒后固定在一个金属外框骨架21上,并用碳绳和碳碳螺杆连接固定。
实施例9:
实施例5所述的一种高效率刹车盘生产设备,其特征是:所述的炉体1材料为Q235碳钢材质,所述的法兰盘15材料为碳钢材质。
实施例10:
一种高效率刹车盘生产设备的应用,本高效率刹车盘生产设备用于生产刹车盘。
实施例11:
上述实施例所述的一种高效率刹车盘生产设备, 设备加热采用电阻加热方式,加热器采用石墨电阻制作而成。加热器包含主加热器和辅助加热器两种。主加热器布置在设备炉体上,是一个圆筒形外加热器,加热器纵向分成上、中、下3 个独立的加热器,每个加热器采用数根石墨管沿圆周均匀分布,形成一个三角形接法鼠笼结构加热器。辅助加热器共三个,布置在炉底上,目的是为了提高炉体内温度的均匀性。
炉体内 进气口压力高,出气口压力低这样在料柱内与真空管道外形成压力差,进行沉积碳。
实施例12:
上述实施例所述的一种高效率刹车盘生产设备,一种能够提高生产效率,保证均温区温度稳定性,进出气压力控制精准可单独调结,包括步骤如下:
1)设备型号炉膛尺寸(mm)CVD-70000L Φ4000×5600 料柱尺寸料柱数量
Φ800×4800 12 个
2) 设计最高温度:1300℃,长期工作温度:800~1100℃;
3) 加热元件:石墨;
4) 加热器布置:外加热器+中心辅助加热器(参加附图4);
5) 配置总功率:1550~1800kw;
6) 装卸料方式:炉底升降出料;
7) 控温精度:升温过程±2℃,保温过程±1℃均温区温度±10℃;
8) 控温方式:外加热器3 段控温+内辅助加热器3 段控温,6 区独立控温;
9) 炉内气氛:天燃气、丙烷、丙烯、氮气等气体;
10) 冷却速度:采用风冷外循环方式加速减温;
11) 设备外形尺寸:16000*14000*15000mm(长*宽*高);
以上所述,仅为本发明较佳的具体实施方式,但本发明的保护范围并不局限于此,任何熟悉本技术领域的技术人员在本发明揭露的技术范围内,可轻易想到的变化或替换,都应涵盖在本发明的保护范围之内。
Claims (9)
1.一种高效率刹车盘生产设备,其组成包括:炉体(1),其特征是:所述的炉体(1)内的外圆设置有9根均匀分布的料柱(2),所述的炉体(1)内的中间部位设置3根中心料柱(3),所述的料柱(2)包裹在圆筒形外加热器(4)内,所述的炉体(1)的底部设置3个辅助加热器(5),所述的辅助加热器(5)作用于所述的中心料柱(3)。
2.根据权利要求1所述的一种高效率刹车盘生产设备,其特征是:所述的圆筒形外加热器(4)分布在所述的炉体(1)内的上部、中部、下部,所述的圆筒形外加热器(4)与所述的辅助加热器(5)均由数根石墨管沿圆周均匀分布,形成一个三角形接法鼠笼结构。
3.根据权利要求2所述的一种高效率刹车盘生产设备,其特征是:所述的炉体(1)的顶部设置有上炉盖(6),所述的上炉盖(6)上设置12个料柱抽气口(7)和12个进气口(8),所述的料柱抽气口(7)与所述的料柱(2)和所述的中心料柱(3)相对应,所述的进气口(8)与所述的料柱(2)和所述的中心料柱(3)相对应,所述的进气口(8)连接压力传感器(9),所述的料柱抽气口(7)连接智能控制蝶阀(10)。
4.根据权利要求3所述的一种高效率刹车盘生产设备,其特征是:所述的炉体(1)的底部设置有12个料柱口(11),所述的料柱口(11)与所述的料柱抽气口(7)一一同轴对应。
5.根据权利要求3所述的一种高效率刹车盘生产设备,其特征是:所述的炉体(1)为立式双层夹套水冷圆筒式结构,由下炉底(12)、下筒节(13)、上筒节(14)和上炉盖(6)组成;所述的下筒节(13)与所述的上筒节(14)之间通过法兰盘(15)连接,所述的炉体(1)内径为4.2m,所述的下筒节(13)与所述的上筒节(14)均设置4个上热电偶测温口(19),所述的法兰盘(15)之间装有O型密封圈,所述的炉体(1)包括外壳体、夹层(22)、内壳体(23),所述的夹层(22)位于所述的外壳体与所述的内壳体(23)之间。
6.根据权利要求4所述的一种高效率刹车盘生产设备,其特征是:所述的料柱口(11)的直径为780mm,所述的料柱口(11)对应安装料柱料台(16),所述的料柱料台(16)的中心设置一个充气气路(24),所述的充气气路(24)内充有氮气和丙烯气。
7.根据权利要求1所述的一种高效率刹车盘生产设备,其特征是:辅助加热器(5)连接水冷电极(17),所述的水冷电极(17)连接所述的圆筒形外加热器(4),所述的炉体(1)的底部设置有6个热电偶测温口(18)。
8.根据权利要求5所述的一种高效率刹车盘生产设备,其特征是:所述的下炉底(12)、连接碳毡保温层(20),所述的碳毡保温层(20)为软碳毡,软碳毡卷筒后固定在一个金属外框骨架(21)上,并用碳绳和碳螺杆连接固定。
9.根据权利要求5所述的一种高效率刹车盘生产设备,其特征是:所述的炉体(1)材料为Q235碳钢材质,所述的法兰盘(15)材料为碳钢材质。
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