CN112782369A - Carburizing treatment monitoring system - Google Patents
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- 238000005255 carburizing Methods 0.000 title claims abstract description 57
- 238000012544 monitoring process Methods 0.000 title claims abstract description 43
- 239000007789 gas Substances 0.000 claims abstract description 225
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims abstract description 108
- 238000000034 method Methods 0.000 claims abstract description 46
- 229910052757 nitrogen Inorganic materials 0.000 claims abstract description 42
- 230000008595 infiltration Effects 0.000 claims abstract description 25
- 238000001764 infiltration Methods 0.000 claims abstract description 25
- 238000010926 purge Methods 0.000 claims abstract description 18
- 238000009792 diffusion process Methods 0.000 claims abstract description 17
- 238000001514 detection method Methods 0.000 claims description 46
- 229910001873 dinitrogen Inorganic materials 0.000 claims description 24
- 238000004868 gas analysis Methods 0.000 claims description 23
- 238000012360 testing method Methods 0.000 claims description 17
- 238000007664 blowing Methods 0.000 claims description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 abstract description 30
- 229910052799 carbon Inorganic materials 0.000 abstract description 30
- 230000000694 effects Effects 0.000 description 16
- 238000004519 manufacturing process Methods 0.000 description 8
- 230000035515 penetration Effects 0.000 description 6
- 238000012545 processing Methods 0.000 description 6
- 238000001914 filtration Methods 0.000 description 5
- 230000001105 regulatory effect Effects 0.000 description 5
- 238000004891 communication Methods 0.000 description 4
- 238000004458 analytical method Methods 0.000 description 3
- 230000001276 controlling effect Effects 0.000 description 3
- 239000002344 surface layer Substances 0.000 description 3
- 229910001209 Low-carbon steel Inorganic materials 0.000 description 2
- 125000004432 carbon atom Chemical group C* 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 239000000428 dust Substances 0.000 description 2
- 238000003379 elimination reaction Methods 0.000 description 2
- 238000011010 flushing procedure Methods 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 239000012535 impurity Substances 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- 229910000677 High-carbon steel Inorganic materials 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000013500 data storage Methods 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 230000003340 mental effect Effects 0.000 description 1
- 239000003595 mist Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000010791 quenching Methods 0.000 description 1
- 230000000171 quenching effect Effects 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000010408 sweeping Methods 0.000 description 1
- 238000005496 tempering Methods 0.000 description 1
- 230000001960 triggered effect Effects 0.000 description 1
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N33/00—Investigating or analysing materials by specific methods not covered by groups G01N1/00 - G01N31/00
- G01N33/0004—Gaseous mixtures, e.g. polluted air
- G01N33/0006—Calibrating gas analysers
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N33/00—Investigating or analysing materials by specific methods not covered by groups G01N1/00 - G01N31/00
- G01N33/0004—Gaseous mixtures, e.g. polluted air
- G01N33/0009—General constructional details of gas analysers, e.g. portable test equipment
- G01N33/0027—General constructional details of gas analysers, e.g. portable test equipment concerning the detector
- G01N33/0036—General constructional details of gas analysers, e.g. portable test equipment concerning the detector specially adapted to detect a particular component
- G01N33/004—CO or CO2
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N33/00—Investigating or analysing materials by specific methods not covered by groups G01N1/00 - G01N31/00
- G01N33/0004—Gaseous mixtures, e.g. polluted air
- G01N33/0009—General constructional details of gas analysers, e.g. portable test equipment
- G01N33/0027—General constructional details of gas analysers, e.g. portable test equipment concerning the detector
- G01N33/0036—General constructional details of gas analysers, e.g. portable test equipment concerning the detector specially adapted to detect a particular component
- G01N33/0047—Organic compounds
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N33/00—Investigating or analysing materials by specific methods not covered by groups G01N1/00 - G01N31/00
- G01N33/0004—Gaseous mixtures, e.g. polluted air
- G01N33/0009—General constructional details of gas analysers, e.g. portable test equipment
- G01N33/0062—General constructional details of gas analysers, e.g. portable test equipment concerning the measuring method or the display, e.g. intermittent measurement or digital display
- G01N33/0063—General constructional details of gas analysers, e.g. portable test equipment concerning the measuring method or the display, e.g. intermittent measurement or digital display using a threshold to release an alarm or displaying means
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- Chemical & Material Sciences (AREA)
- Life Sciences & Earth Sciences (AREA)
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- Food Science & Technology (AREA)
- Combustion & Propulsion (AREA)
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- Analytical Chemistry (AREA)
- Biochemistry (AREA)
- General Health & Medical Sciences (AREA)
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Abstract
The invention discloses a carburizing treatment monitoring system, which relates to the technical field of monitoring systems and solves the problem of poor accuracy in adjusting and monitoring carbon potential. The technical key points are as follows: a carburizing treatment monitoring system comprises a nitrogen tank, a zero gas tank, a standard gas tank, a gas pump and a gas analyzer. The carbon potential is adjusted by adjusting the CH4 gas concentration, so that the requirement of the carbon potential in the carburizing treatment process is met. A feasible method for adjusting and monitoring the carbon potential is added for the prior art, so that the method for adjusting and monitoring the carbon potential is enriched. Also disclosed is a carburization monitoring method comprising the steps of: zero point calibration; calibrating the slope; automatic nitrogen purging; the early stage of the strong infiltration stage; the later stage of the strong infiltration stage; and (4) a diffusion stage. Through slope calibration and zero calibration, the influence of gas in the carburizing furnace on the calibration of a gas analyzer is avoided, and the advantages of improving the regulation of carbon potential and having higher monitoring accuracy are achieved.
Description
Technical Field
The invention relates to the technical field of monitoring systems, in particular to a carburizing monitoring system.
Background
Carburizing means a process of infiltrating carbon atoms into a steel surface layer, and is a process of enabling a low-carbon steel workpiece to have a high-carbon steel surface layer, and then performing heat treatment procedures such as quenching, low-temperature tempering and the like to enable the surface layer of the workpiece to have high hardness and wear resistance, and the central part of the workpiece still maintains the toughness and plasticity of the low-carbon steel. The carburizing process is widely used for machining parts such as gears, shafts, camshafts and the like of airplanes, automobiles, tractors and the like. Gas carburizing is a carburizing treatment process using active gas containing carbon atoms as a carbon-containing medium, and in order to ensure the carburizing treatment effect of a workpiece, the stability and accuracy of the gas content need to be ensured.
In the prior art, the gas in the carburizing furnace is pumped out, a gas sample is input into a furnace gas analyzer, and the gas sample is detected by the furnace gas analyzer, so that the function of detecting the gas components in the carburizing furnace is realized. The Chinese patent application with publication number CN109085042A discloses a portable furnace gas analyzer, which comprises a power supply system and a gas analysis system, wherein the power supply system supplies power to the gas analysis system, the gas analysis system comprises a gas processing module, a gas flow regulating module, an analysis processing module and a display module, the gas processing module comprises a gas inlet unit, a primary filtering unit, a gas flow display unit, a secondary filtering unit and a tertiary filtering unit which are sequentially connected through a gas pipe, and the analysis processing module comprises a sensor unit, an exhaust unit, an atmosphere calculator and a data storage chip, so that the components in the atmosphere of a heat treatment furnace are detected. The CO sensor module, the CO2 sensor module and the CH4 sensor module of the sensor units respectively sense CO, CO2 and CH4 in the furnace gas, and the carbon potential Cp value is calculated by the formula lg [ (% CO) 2/(% CO2) ], P ═ 6311/T +10.165+ lgCp- (1-Cp)2 × (350/T +1.86), wherein% CO means the content of CO in the gas,% CO2 means the content of CO2 in the gas, and P and T are known values.
At present, the carbon potential in the carburizing treatment process is regulated by controlling and monitoring the content of CO and the content of CO2, the regulating and monitoring mode is single, certain limitation is realized, and the inaccurate regulation and monitoring of the carbon potential are easily caused. Therefore, the prior art has the problem of poor accuracy in adjusting and monitoring the carbon potential.
Disclosure of Invention
In order to overcome the above-mentioned drawbacks of the prior art, it is an object of the present invention to provide a carburization process monitoring system having the advantage of high accuracy in adjustment and monitoring of the carbon potential.
The technical scheme adopted by the invention for solving the technical problems is as follows:
the utility model provides a carburization monitoring system, includes nitrogen gas jar, zero gas jar, standard gas jar, air pump and gas analysis appearance, the inlet end of air pump is equipped with the intake pipe with the carburizing furnace intercommunication, the exhaust end intercommunication of air pump has the test tube, gas analysis appearance and test tube intercommunication, the condenser that is located between gas analysis appearance and the air pump is installed to the test tube, zero gas jar and standard gas jar all communicate between gas analysis appearance and air pump with the test tube, nitrogen gas jar and intake pipe intercommunication, the intake pipe is equipped with the solenoid valve that admits air, be equipped with the nitrogen gas solenoid valve between nitrogen gas jar and the intake pipe, be equipped with the solenoid valve at zero point between zero gas jar and the test tube, be equipped with the standard solenoid valve between standard gas jar and the test tube, the storage has nitrogen gas in the zero gas jar, the calibration mist is stored in the standard.
As a further improvement of the invention: still include the circuit breaker subassembly, circuit breaker subassembly and external power source electric connection, circuit breaker subassembly electric connection has the power supply module, the power supply module respectively with air inlet solenoid valve, nitrogen gas solenoid valve, solenoid valve at zero point, standard solenoid valve and gas analysis appearance electric connection.
As a further improvement of the invention: the circuit breaker assembly comprises a first circuit breaker, a second circuit breaker and a third circuit breaker, the first circuit breaker is electrically connected with the power supply module, the second circuit breaker is electrically connected with a socket, and the third circuit breaker is electrically connected with a refrigerator arranged at the gas analyzer.
As a further improvement of the invention: still include control module, control module respectively with admit air solenoid valve, nitrogen gas solenoid valve, zero solenoid valve and standard solenoid valve electric connection, be equipped with between air pump and the gas analysis appearance and detect the flowmeter, control module and detection flowmeter electric connection, the air pump is equipped with the bypass flowmeter, the both ends of bypass flowmeter communicate with the both ends of air pump respectively.
As a further improvement of the invention: the control module is electrically connected with the gas analyzer and the alarm device.
As a further improvement of the invention: the gas analyzer is provided with a pressure difference detector, and two ends of the pressure difference detector are respectively communicated with two ends of the gas analyzer.
A carburization process monitoring method comprising the steps of:
zero point calibration: closing the air inlet electromagnetic valve and the standard electromagnetic valve, opening the zero electromagnetic valve, introducing nitrogen in the zero gas tank into the detection pipe and the gas analyzer, and performing zero calibration on the gas analyzer through the nitrogen;
slope calibration: closing the air inlet electromagnetic valve and the zero electromagnetic valve, opening the standard electromagnetic valve, introducing the standard mixed gas in the standard gas tank into the detection pipe and the gas analyzer, detecting the standard mixed gas by using the gas analyzer, repeating the step of zero calibration if the gas analyzer cannot accurately detect the gas concentration of the standard mixed gas, and performing the next step if the gas analyzer can accurately detect the gas concentration of the standard mixed gas;
and (3) strong infiltration early stage: inputting a gas sample in the carburizing furnace into a gas analyzer through an air inlet pipe and a detection pipe by using an air pump, detecting the CH4 value of the gas sample by using the gas analyzer, adjusting the CH4 value in the carburizing furnace to increase the CH4 value, and detecting the Cp value of the gas sample by using the gas analyzer;
and (3) strong infiltration later stage: inputting a gas sample in the carburizing furnace into a gas analyzer through an air inlet pipe and a detection pipe by using an air pump, detecting the CH4 value of the gas sample by using the gas analyzer, reducing the CH4 value by adjusting the CH4 value in the carburizing furnace, and detecting the Cp value of the gas sample by using the gas analyzer;
and (3) a diffusion stage: the gas sample in the carburizing furnace is input into a gas analyzer through an air inlet pipe and a detection pipe by an air pump, the CH4 value of the gas sample is detected by the gas analyzer, the CH4 value in the carburizing furnace is adjusted to keep the CH4 value stable, and the Cp value of the gas sample is detected by the gas analyzer.
As a further improvement of the invention: before the step of the strong infiltration early stage, the method also comprises the following steps:
automatic nitrogen purging: and if the flow detection value is smaller than the purging threshold value, the control module controls the air inlet electromagnetic valve to be closed and controls the nitrogen electromagnetic valve to be opened, so that nitrogen in the nitrogen tank flows to the air inlet pipe to perform reverse purging.
As a further improvement of the invention: in the step of automatic nitrogen purging, the method further comprises the following steps:
if the flow detection value is still lower than the purging threshold value after the nitrogen is subjected to back flushing, the control module sends an instruction to the alarm device to trigger the alarm device to send out an alarm.
As a further improvement of the invention: in the step of the early stage of the strong infiltration, the method also comprises the following steps:
the strong infiltration time is 180 minutes, the CH4 value is 7.9 percent when the strong infiltration is carried out for 30 minutes, the CH4 value is 8.91 percent when the strong infiltration is carried out for 60 minutes, and the CH4 value is 9.14 percent when the strong infiltration is carried out for 90 minutes;
in the step of the later stage of the strong infiltration, the method also comprises the following steps: the CH4 value is 9.08 percent at the time of strong permeation for 120 minutes, the CH4 value is 7.81 percent at the time of strong permeation for 150 minutes, and the CH4 value is 7.41 percent at the time of strong permeation for 180 minutes;
in the step of the diffusion stage, the method further comprises the following steps: the time period for the diffusion was 120 minutes, the CH4 value was 4.58% at 30 minutes, the CH4 value was 4.74% at 60 minutes, the CH4 value was 4.78% at 90 minutes, and the CH4 value was 4.72% at 120 minutes.
Compared with the prior art, the invention has the beneficial effects that:
the concentration of CH4 gas in the carburizing furnace is adaptively adjusted according to the carbon potential of the gas in the carburizing furnace, and the carbon potential is adjusted by adjusting the concentration of CH4 gas, so that the requirement on the carbon potential in the carburizing treatment process is met. A feasible method for adjusting and monitoring the carbon potential is added for the prior art, so that the method for adjusting and monitoring the carbon potential is enriched.
Through slope calibration and zero calibration, the influence of gas in the carburizing furnace on the calibration of the gas analyzer can be avoided, the accuracy of calibrating the gas analyzer is improved, and the advantages of improving the adjustment of carbon potential and higher monitoring accuracy are achieved.
Control the solenoid valve and close and control the nitrogen gas solenoid valve and open according to flow detection value through control module, make the nitrogen gas in the nitrogen gas jar flow to the intake pipe and carry out reverse sweeping, make stifled object in the intake pipe blow off the intake pipe by nitrogen gas to can play the effect of self-repairing trouble, play the effect of making things convenient for production, reach the effect that improves production efficiency.
Through control module and alarm device's setting, can send out the police dispatch newspaper more conveniently to control module can start restarting the procedure according to alarm information when CO sensor module, CO2 sensor module and CH4 sensor module communication are wrong, can improve the ability of system self-elimination trouble to a certain extent, reaches the effect of convenient production, plays the effect that improves production efficiency.
Drawings
FIG. 1 is a schematic diagram of a carburization monitoring system according to an embodiment of the present disclosure;
fig. 2 is a schematic diagram of a circuit connection structure of a circuit breaker assembly according to an embodiment of the present disclosure;
FIG. 3 is a schematic flow chart of a carburization monitoring method according to an embodiment of the present application;
FIG. 4 is a graph of carbon potential Cp and CH4 values versus processing time for an example of the present application.
Reference numerals: 11. an air pump; 12. a detection tube; 13. a gas analyzer; 14. a condenser; 15. detecting a flow device; 16. an exhaust pipe; 17. an evacuation flow meter; 18. a precision filter; 19. a pressure differential detector; 21. an air inlet pipe; 22. a nitrogen tank; 23. an air inlet solenoid valve; 24. a nitrogen solenoid valve; 25. a first filter; 26. a second filter; 27. a third filter; 28. a bypass flow device; 31. a zero gas tank; 32. a standard gas tank; 33. a zero point solenoid valve; 34. a standard solenoid valve; 35. a needle valve; 36. a zero-point pressure regulating valve; 37. a standard pressure regulating valve; 41. a circuit breaker assembly; 42. a first circuit breaker; 43. a second circuit breaker; 44. a third circuit breaker; 45. a socket; 46. a refrigerator; 47. a power supply module; 48. a control module; 49. an alarm device; 51. a solenoid valve power supply element; 52. and detecting the electromagnetic valve.
Detailed Description
The invention will now be further described with reference to the accompanying description and examples:
example (b):
the utility model provides a carburization monitoring system, as shown in fig. 1 to 4, including nitrogen gas jar 22, gas pitcher 31 at zero point, standard gas pitcher 32, air pump 11, gas analysis appearance 13, circuit breaker subassembly 41 and control module 48, the inlet end of air pump 11 is equipped with the intake pipe 21 with the carburizing furnace intercommunication, the exhaust end intercommunication of air pump 11 has test tube 12, gas analysis appearance 13 and test tube 12 intercommunication, test tube 12 installs the condenser 14 that is located between gas analysis appearance 13 and the air pump 11, reduce the steam that gets into in gas analysis appearance 13 through condenser 14. Zero gas tank 31 and standard gas tank 32 all communicate between gas analyzer 13 and air pump 11 with detecting tube 12, nitrogen gas tank 22 and intake pipe 21 intercommunication, intake pipe 21 is equipped with air inlet solenoid valve 23, be equipped with nitrogen gas solenoid valve 24 between nitrogen gas tank 22 and the intake pipe 21, be equipped with zero solenoid valve 33 between zero gas tank 31 and the detecting tube 12, zero gas tank 31 intercommunication has zero air-vent valve 36, be equipped with standard solenoid valve 34 between standard gas tank 32 and the detecting tube 12, standard gas tank 32 intercommunication has standard air-vent valve 37, store nitrogen gas in the gas tank 31 of zero, the internal storage of standard gas tank 32 has calibration gas mixture. The detection pipe 12 is communicated with a needle valve 35, the zero-point gas tank 31 and the standard gas tank 32 are respectively communicated with the needle valve 35, and the gas analyzer 13 is provided with a pressure difference detector 19. Two ends of the pressure difference detector 19 are respectively communicated with two ends of the gas analyzer 13, the pressure difference detector 19 is used for detecting the pressure difference at two ends of the gas analyzer 13, and the pressure difference detector 19 is arranged to conveniently detect the working state of the gas analyzer 13. The air inlet pipe 21 is provided with a first filter 25, a second filter 26 and a third filter 27, and the first filter 25, the second filter 26 and the third filter 27 are used for filtering the air in the air inlet pipe 21 and reducing impurities such as dust entering the detection pipe 12. The detection tube 12 is provided with a precision filter 18, the precision filter 18 is used for filtering the gas in the detection tube 12 and reducing impurities such as dust entering the gas analyzer 13, and the detection tube 12 is provided with a detection solenoid valve 52.
The exhaust end of the air pump 11 is communicated with an exhaust pipe 16, the exhaust pipe 16 is communicated with an emptying flowmeter 17, when gas is not required to be input into the detection pipe 12, the gas of the air pump 11 can be exhausted through the emptying pipe, and the effect of convenient use is achieved.
The gas analyzer 13 is provided with a CO sensor module, a CO2 sensor module, and a CH4 sensor module inside, and can monitor a CO value, a CO2 value, and a CH4 value respectively by the CO sensor module, the CO2 sensor module, and the CH4 sensor module, and in this embodiment, the CO value, the CO2 value, and the CH4 value respectively indicate a CO gas concentration, a CO2 gas concentration, and a CH4 gas concentration. The nitrogen tank 22 stores high-purity nitrogen, and the standard gas tank 32 stores standard mixed gas.
The air pump 11 is through the gas in intake pipe 21 will carburizing stove take out, and will take out the gaseous sample through the test tube 12 carry gas analyzer 13 in, use gas analyzer 13 to carry out analysis and monitoring to gas sample, thereby can obtain the CO value, CO2 value and CH4 value, the realization is to carrying out the function of monitoring to the gaseous carbon potential in the carburizing stove, and can be according to the gaseous carbon potential adaptability in the carburizing stove CH4 gas concentration in the carburizing stove, and through adjusting CH4 gas concentration adjustment carbon potential, satisfy the demand to carbon potential in the carburization processing process.
The circuit breaker assembly 41 is electrically connected with an external power supply, the circuit breaker assembly 41 is electrically connected with a power supply module 47, the power supply module 47 is electrically connected with the gas analyzer 13, the power supply module 47 is electrically connected with an electromagnetic valve power supply element 51, the electromagnetic valve power supply element 51 is respectively connected with the air inlet electromagnetic valve 23, the nitrogen electromagnetic valve 24, the zero electromagnetic valve 33 and the standard electromagnetic valve 34, in this embodiment, the electromagnetic valve power supply element 51 adopts a hub, and the electromagnetic valve power supply element 51 is used for supplying the air inlet electromagnetic valve 23, the nitrogen electromagnetic valve 24, the zero electromagnetic valve 33 and the standard electromagnetic valve 34, so that the function of supplying power to the air inlet electromagnetic valve 23, the nitrogen electromagnetic valve 24, the zero electromagnetic valve 33 and the standard electromagnetic valve 34. The power supply module 47 is used for converting 220V ac power into 24V dc power. The power is supplied to the external power source through the circuit breaker assembly 41, the circuit breaker assembly 41 is electrically connected with the power supply module 47, and then the power supply module 47 is electrically connected with the air inlet electromagnetic valve 23, the nitrogen electromagnetic valve 24, the zero electromagnetic valve 33, the standard electromagnetic valve 34 and the gas analyzer 13 respectively, so that the function of electrically connecting and supplying power to the air inlet electromagnetic valve 23, the nitrogen electromagnetic valve 24, the zero electromagnetic valve 33, the standard electromagnetic valve 34 and the gas analyzer 13 is realized. The circuit breaker assembly 41 includes a first circuit breaker 42, a second circuit breaker 43 and a third circuit breaker 44, the first circuit breaker 42 is electrically connected with a power supply module 47, the second circuit breaker 43 is electrically connected with a socket 45, and the third circuit breaker 44 is electrically connected with a refrigerator 46 installed at the gas analyzer 13.
The control module 48 is respectively electrically connected with the air inlet electromagnetic valve 23, the nitrogen electromagnetic valve 24, the zero electromagnetic valve 33 and the standard electromagnetic valve 34, the flow detection device 15 is arranged between the air pump 11 and the gas analyzer 13, the control module 48 is electrically connected with the flow detection device 15, the air pump 11 is provided with a bypass flow device 28, two ends of the bypass flow device 28 are respectively communicated with two ends of the air pump 11, the bypass flow device 28 is connected with the air pump 11 in parallel, and the air pump 11 is protected by circulating air inside the bypass flow device 28. In the present embodiment, the control module 48 is a PLC module. The control module 48 is electrically connected to the intake solenoid valve 23, the nitrogen solenoid valve 24, the zero solenoid valve 33, and the standard solenoid valve 34, so that the intake solenoid valve 23, the nitrogen solenoid valve 24, the zero solenoid valve 33, and the standard solenoid valve 34 can be controlled by the control module 48. The detection flow meter 15 is used to detect the amount of air flow at both ends of the air pump 11. The control module 48 is internally preset with a purging threshold, the flow rate detector 15 detects the air flow rate of the air pump 11, the flow rate detector 15 sends a flow rate detection value which is reduced along with the reduction of the air flow rate of the air pump 11 to the control module 48, and if the flow rate detection value is smaller than the purging threshold, the air flow rate of the air pump 11 is insufficient.
A restart program is preset in the control module 48, and when the restart program is started, the control module 48 controls the gas analyzer 13 to restart. If the communication errors of the CO sensor module, the CO2 sensor module and the CH4 sensor module occur, the gas analyzer 13 sends alarm information to the control module 48, the control module 48 is triggered to start a restart program, and the gas analyzer 13 is restarted. And if the alarm information is not eliminated after the restarting program is finished, restarting the restarting program again. If the number of times of restarting the program reaches 3 times, the control module 48 sends an instruction to the alarm device 49 to trigger the alarm device 49 to send an alarm.
A carburization process monitoring method comprising the steps of:
s1, zero calibration: closing the air inlet electromagnetic valve 23 and the standard electromagnetic valve 34, opening the zero point electromagnetic valve 33, introducing nitrogen in the zero point air tank 31 into the detection pipe 12 and the gas analyzer 13, and performing zero point calibration on the gas analyzer 13 through the nitrogen;
s2, slope calibration: closing the air inlet electromagnetic valve 23 and the zero point electromagnetic valve 33, opening the standard electromagnetic valve 34, introducing the standard mixed gas in the standard gas tank 32 into the detection pipe 12 and the gas analyzer 13, detecting the standard mixed gas by using the gas analyzer 13, wherein the components of the standard mixed gas are known by an operator, repeating the step of zero point calibration if the gas analyzer 13 cannot accurately detect the gas concentration of the standard mixed gas, and performing the next step if the gas analyzer 13 can accurately detect the gas concentration of the standard mixed gas;
s3, automatic nitrogen purging: setting a purging threshold value in the control module 48, detecting the air flow of the air pump 11 by the flow meter 15, sending a flow detection value reduced along with the reduction of the air flow of the air pump 11 to the control module 48 by the flow meter 15, if the flow detection value is smaller than the purging threshold value, controlling the air inlet electromagnetic valve 23 to be closed and controlling the nitrogen electromagnetic valve 24 to be opened by the control module 48, and enabling the nitrogen in the nitrogen tank 22 to flow to the air inlet pipe 21 for reverse purging; if the flow detection value is still lower than the purging threshold value after the nitrogen is subjected to back flushing, the control module 48 sends an instruction to the alarm device 49 to trigger the alarm device 49 to send an alarm;
s4, strong infiltration early stage: inputting the gas sample in the carburizing furnace into a gas analyzer 13 through an air inlet pipe 21 and a detection pipe 12 by using an air pump 11, detecting the CH4 value of the gas sample by using the gas analyzer 13, adjusting the CH4 value in the carburizing furnace to increase the CH4 value, and detecting the Cp value of the gas sample by using the gas analyzer 13; the strong infiltration time is 180 minutes, the CH4 value is 7.9 percent when the strong infiltration is carried out for 30 minutes, the CH4 value is 8.91 percent when the strong infiltration is carried out for 60 minutes, and the CH4 value is 9.14 percent when the strong infiltration is carried out for 90 minutes;
s5, strong infiltration later stage: inputting the gas sample in the carburizing furnace into a gas analyzer 13 through an air inlet pipe 21 and a detection pipe 12 by using an air pump 11, detecting the CH4 value of the gas sample by using the gas analyzer 13, reducing the CH4 value by adjusting the CH4 value in the carburizing furnace, and detecting the Cp value of the gas sample by using the gas analyzer 13; in the step of the later stage of the strong infiltration, the method also comprises the following steps: the CH4 value is 9.08 percent at the time of strong permeation for 120 minutes, the CH4 value is 7.81 percent at the time of strong permeation for 150 minutes, and the CH4 value is 7.41 percent at the time of strong permeation for 180 minutes;
s6, diffusion stage: inputting the gas sample in the carburizing furnace into a gas analyzer 13 through an air inlet pipe 21 and a detection pipe 12 by using an air pump 11, detecting the CH4 value of the gas sample by using the gas analyzer 13, keeping the CH4 value stable by adjusting the CH4 value in the carburizing furnace, and detecting the Cp value of the gas sample by using the gas analyzer 13; in the step of the diffusion stage, the method further comprises the following steps: the time period for the diffusion was 120 minutes, the CH4 value was 4.58% at 30 minutes, the CH4 value was 4.74% at 60 minutes, the CH4 value was 4.78% at 90 minutes, and the CH4 value was 4.72% at 120 minutes.
In the carburizing treatment, strong carburizing and carburizing diffusion through carburizing are required. In this embodiment, the time period of the hard carburizing is 180 minutes, the time period of the carburizing and diffusing is 120 minutes, and the monitoring data obtained in the carburizing process of the workpiece is as follows:
when the strong penetration is carried out for 30 minutes, the CH4 value is adjusted to be 7.9 percent, and the carburized Cp value is 0.513 percent; when the strong penetration is carried out for 60 minutes, the CH4 value is adjusted to be 8.91 percent, and the carburized Cp value is 0.671 percent; when the strong penetration is carried out for 90 minutes, the CH4 value is adjusted to 9.14 percent, and the carburized Cp value is 0.833 percent;
when the strong penetration lasts for 120 minutes, the CH4 value is adjusted to 9.08 percent, and the carburized Cp value is 0.948 percent; when the strong penetration is carried out for 150 minutes, the CH4 value is adjusted to be 7.81 percent, and the carburized Cp value is 0.968 percent; when the strong cementation is carried out for 180 minutes, the CH4 value is adjusted to be 7.41 percent, and the carburized Cp value is 0.979 percent;
the time period for carrying out the carburization diffusion is 120 minutes, and when the carburization diffusion is 30 minutes, the CH4 value is adjusted to 4.58 percent, and the carburization Cp value is 0.857 percent; when the carburization diffusion is carried out for 60 minutes, the CH4 value is adjusted to 4.74 percent, and the carburization Cp value is adjusted to 0.839 percent; when the carburization diffusion was carried out for 90 minutes, the CH4 value was adjusted to 4.78%, and the carburization Cp value was adjusted to 0.83%; the value of CH4 was adjusted to 4.72% and the value of Cp for carburization was adjusted to 0.833% at 120 minutes of carburization diffusion.
The values of carburized Cp and CH4 are shown in Table 1:
TABLE 1 carburization Cp value and CH4 value
In the early stage of strong cementation, the CH4 value is increased, and the carburized Cp value is increased; the CH4 value is reduced in the later stage of strong penetration, and the Cp value is kept within the range of the set value; the CH4 value remains substantially stable throughout the diffusion carburization stage, as does the Cp value. Thereby achieving the effect of adjusting the value of carburized Cp by adjusting the value of CH 4.
The embodiment has the following advantages:
the concentration of CH4 gas in the carburizing furnace is adaptively adjusted according to the carbon potential of the gas in the carburizing furnace, and the carbon potential is adjusted by adjusting the concentration of CH4 gas, so that the requirement on the carbon potential in the carburizing treatment process is met. A feasible method for adjusting and monitoring the carbon potential is added for the prior art, so that the method for adjusting and monitoring the carbon potential is enriched.
The electromagnetic valve is closed, and the gas in the carburizing furnace is prevented from entering a gas analyzer 13 through a detection pipe 12. And opening the zero electromagnetic valve 33 and closing the standard electromagnetic valve 34 to lead the high-purity nitrogen in the nitrogen tank 22 to the gas analyzer 13, so that the gas analyzer 13 can be zeroed to realize the function of zero calibration. Thereby, the influence of the gas in the carburizing furnace can be avoided in the process of zeroing the gas analyzer 13. Then, the standard electromagnetic valve 34 is opened, and the zero point electromagnetic valve 33 is closed, so that the standard mixed gas in the standard gas tank 32 is introduced into the gas analyzer 13, thereby calibrating the gas analyzer 13 and realizing the slope calibration function. The gas in the carburizing furnace can be prevented from influencing the calibration of the gas analyzer 13, the accuracy of calibrating the gas analyzer 13 is improved, and the advantages of high adjustment and monitoring accuracy of carbon potential are achieved.
Control the air inlet solenoid valve 23 to close and control the nitrogen solenoid valve 24 to open according to the flow detection value through the control module 48, make the nitrogen gas in the nitrogen tank 22 flow to the intake pipe 21 and carry out reverse blowing, make the object of stifled in the intake pipe 21 blow off the intake pipe 21 by the nitrogen gas to can play the effect of self-repairing trouble, play the effect of making things convenient for production, reach the effect that improves production efficiency.
Through control module 48 and alarm device 49's setting, can send out the police dispatch newspaper more conveniently to control module 48 can start restarting the procedure according to alarm information when CO sensor module, CO2 sensor module and CH4 sensor module communication are wrong, can improve the ability of system self-elimination trouble to a certain extent, reaches the effect of convenient production, plays the effect that improves production efficiency.
Adjust the gas flow that zero point gas pitcher 31 and standard gas pitcher 32 let in the test tube 12 through needle valve 35, play the effect of facilitating the use and conveniently adjusting, can let in the gas flow control that test tube 12 was gone into to zero point gas pitcher 31 and standard gas pitcher 32 through needle valve 35 at the within range that is 1.5L per minute ~ 2L per minute.
An element can be said to be "connected" to another element, it can be directly connected to the other element or intervening elements may also be present. The terms "mounted," "connected," and "connected" are to be construed broadly and may include, for example, mechanical or electrical connections, communications between two elements, direct connections, indirect connections through intermediaries, and the like. The terms "vertical," "horizontal," "upper," "lower," "left," "right," and the like as used herein are for illustrative purposes only and do not denote a unique embodiment.
In summary, after reading the present disclosure, those skilled in the art can make various other corresponding changes without creative mental labor according to the technical solutions and concepts of the present disclosure, and all of them are within the protection scope of the present disclosure.
Claims (10)
1. A carburization process monitoring system characterized by: including nitrogen gas jar (22), zero gas jar (31), standard gas jar (32), air pump (11) and gas analysis appearance (13), the inlet end of air pump (11) is equipped with intake pipe (21) with the carburizing furnace intercommunication, the exhaust end intercommunication of air pump (11) has test tube (12), gas analysis appearance (13) and test tube (12) intercommunication, condenser (14) that are located between gas analysis appearance (13) and air pump (11) are installed to test tube (12), zero gas jar (31) and standard gas jar (32) all communicate between gas analysis appearance (13) and air pump (11) with test tube (12), nitrogen gas jar (22) and intake pipe (21) intercommunication, intake pipe (21) are equipped with air inlet solenoid valve (23), be equipped with nitrogen gas solenoid valve (24) between nitrogen gas jar (22) and intake pipe (21), be equipped with zero solenoid valve (33) between gas jar (31) and test tube (12), and a standard electromagnetic valve (34) is arranged between the standard gas tank (32) and the detection pipe (12), nitrogen is stored in the zero gas tank (31), and a calibration mixed gas is stored in the standard gas tank (32).
2. A carburization process monitoring system in accordance with claim 1, wherein: still include circuit breaker subassembly (41), circuit breaker subassembly (41) and external power source electric connection, circuit breaker subassembly (41) electric connection has power supply module (47), power supply module (47) respectively with air inlet solenoid valve (23), nitrogen gas solenoid valve (24), solenoid valve (33), standard solenoid valve (34) and gas analysis appearance (13) electric connection at zero point.
3. A carburization monitoring system in accordance with claim 2 wherein: the circuit breaker subassembly (41) includes first circuit breaker (42), second circuit breaker (43) and third circuit breaker (44), first circuit breaker (42) and power supply module (47) electric connection, second circuit breaker (43) electric connection has socket (45), third circuit breaker (44) electric connection has refrigerator (46) of installing in gas analysis appearance (13) department.
4. A carburization process monitoring system in accordance with claim 1, wherein: still include control module (48), control module (48) respectively with admit air solenoid valve (23), nitrogen gas solenoid valve (24), zero solenoid valve (33) and standard solenoid valve (34) electric connection, be equipped with between air pump (11) and gas analysis appearance (13) and detect flowmeter (15), control module (48) and detection flowmeter (15) electric connection, air pump (11) are equipped with bypass flowmeter (28), the both ends of bypass flowmeter (28) communicate with the both ends of air pump (11) respectively.
5. A carburization monitoring system according to claim 4, characterized in that: the control module (48) is electrically connected with the gas analyzer (13), and the control module (48) is electrically connected with an alarm device (49).
6. A carburization process monitoring system in accordance with claim 1, wherein: the detecting tube (12) is communicated with a needle valve (35), the zero-point gas tank (31) and the standard gas tank (32) are respectively communicated with the needle valve (35), the gas analyzer (13) is provided with a pressure difference detector (19), and two ends of the pressure difference detector (19) are respectively communicated with two ends of the gas analyzer (13).
7. A carburization monitoring method characterized by comprising the steps of:
zero point calibration: closing the air inlet electromagnetic valve (23) and the standard electromagnetic valve (34), opening the zero electromagnetic valve (33), introducing nitrogen in the zero air tank (31) into the detection pipe (12) and the gas analyzer (13), and performing zero calibration on the gas analyzer (13) through the nitrogen;
slope calibration: closing the air inlet electromagnetic valve (23) and the zero electromagnetic valve (33), opening the standard electromagnetic valve (34), introducing the standard mixed gas in the standard gas tank (32) into the detection pipe (12) and the gas analyzer (13), detecting the standard mixed gas by using the gas analyzer (13), repeating the step of zero calibration if the gas analyzer (13) cannot accurately detect the gas concentration of the standard mixed gas, and performing the next step if the gas analyzer (13) can accurately detect the gas concentration of the standard mixed gas;
and (3) strong infiltration early stage: inputting a gas sample in the carburizing furnace into a gas analyzer (13) through an air inlet pipe (21) and a detection pipe (12) by using an air pump (11), detecting the CH4 value of the gas sample by using the gas analyzer (13), adjusting the CH4 value in the carburizing furnace to increase the CH4 value, and detecting the Cp value of the gas sample by using the gas analyzer (13);
and (3) strong infiltration later stage: inputting a gas sample in the carburizing furnace into a gas analyzer (13) through an air inlet pipe (21) and a detection pipe (12) by using an air pump (11), detecting the CH4 value of the gas sample by using the gas analyzer (13), reducing the CH4 value by adjusting the CH4 value in the carburizing furnace, and detecting the Cp value of the gas sample by using the gas analyzer (13);
and (3) a diffusion stage: a gas sample in a carburizing furnace is introduced into a gas analyzer (13) through an inlet pipe (21) and a detection pipe (12) by an air pump (11), the CH4 value of the gas sample is detected by the gas analyzer (13), the CH4 value is kept stable by adjusting the CH4 value in the carburizing furnace, and the Cp value of the gas sample is detected by the gas analyzer (13).
8. A carburization monitoring method according to claim 7, characterized by, before the step of the early stage of the high-strength carburization, further comprising the steps of:
automatic nitrogen purging: the method comprises the steps that a purging threshold value is arranged in a control module (48), a flow meter (15) is detected to detect the air flow of an air pump (11), the flow meter (15) is detected to send a flow detection value which is reduced along with the reduction of the air flow of the air pump (11) to the control module (48), and if the flow detection value is smaller than the purging threshold value, the control module (48) controls an air inlet electromagnetic valve (23) to be closed and controls a nitrogen electromagnetic valve (24) to be opened, so that nitrogen in a nitrogen tank (22) flows to an air inlet pipe (21) to be purged reversely.
9. A carburization process monitoring method according to claim 8, characterized by further comprising, in the step of automatically purging with nitrogen, the steps of:
if the flow detection value is still lower than the purging threshold value after the nitrogen is subjected to back blowing, the control module (48) sends an instruction to the alarm device (49) to trigger the alarm device (49) to send an alarm.
10. A carburization monitoring method according to claim 7, characterized by further comprising, in the step of the early stage of the high-strength carburization, the steps of:
the strong infiltration time is 180 minutes, the CH4 value is 7.9 percent when the strong infiltration is carried out for 30 minutes, the CH4 value is 8.91 percent when the strong infiltration is carried out for 60 minutes, and the CH4 value is 9.14 percent when the strong infiltration is carried out for 90 minutes;
in the step of the later stage of the strong infiltration, the method also comprises the following steps: the CH4 value is 9.08 percent at the time of strong permeation for 120 minutes, the CH4 value is 7.81 percent at the time of strong permeation for 150 minutes, and the CH4 value is 7.41 percent at the time of strong permeation for 180 minutes;
in the step of the diffusion stage, the method further comprises the following steps: the time period for the diffusion was 120 minutes, the CH4 value was 4.58% at 30 minutes, the CH4 value was 4.74% at 60 minutes, the CH4 value was 4.78% at 90 minutes, and the CH4 value was 4.72% at 120 minutes.
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