News

Sept 10th,2010: G.M MAI was invited by CHINA NONFERROS METALS INDUSTRY ASSOCIATION for report of latest quenching system .

上海精密淬火技術(shù)報(bào)告會(huì)

擠壓鋁型材在線精密淬火技術(shù)論文
 Shanghai Precision Quenching Technology Report

High Precise Quenching Technology for Aluminium Extrusion System

作者： 麥鴻杰 （佛山市南海賽福鋁材設(shè)備有限公司^①總經(jīng)理）

Reporter: Mr. Hongjie Mai (General manager of Foshan Nanhai Save Aluminium Equipment Co., Ltd. ^①)

論文發(fā)布時(shí)間: 2010-09-10; 地點(diǎn): 上海市

Date: Sep 10, 2010; Shanghai

 

關(guān)鍵詞：擠壓，鋁型材，尺寸精度，在線淬火，淬火（冷卻）強(qiáng)度，冷卻速度，淬火對(duì)冷卻速度敏感性

Keywords: aluminium extrusion, aluminium profile, dimensional accuracy, online quenching, quenching (cooling) intensity, cooling rate, quenching sensitivity to cooling speed

內(nèi)容摘要：

近年來，隨著國民經(jīng)濟(jì)的快速發(fā)展，鋁型材在工業(yè)上的應(yīng)用日益廣泛。同時(shí)，對(duì)鋁型材的要求越來越高，主要表現(xiàn)在：1、型材的截面要求越來越寬，形狀越來越復(fù)雜；2、尺寸精度越來越嚴(yán)格；3、力學(xué)性能越來越高。要滿足市場(chǎng)對(duì)鋁型材產(chǎn)品的要求，就給型材的生產(chǎn)工藝和裝備提出更高的要求，特別是在線淬火環(huán)節(jié)。因?yàn)橐剐筒倪_(dá)到高的力學(xué)性能，型材淬火時(shí)的冷卻速度必須確保過飽和固溶體被固定下來不分解，防止強(qiáng)化相析出，以免降低淬火時(shí)效后的力學(xué)性能。因此，淬火時(shí)的冷卻速度應(yīng)越快越好。但是冷卻速度越快，淬火型材的殘余應(yīng)力和殘余變形也越大，型材的尺寸精度就無法保證。所以，要同時(shí)滿足以上三方面的要素，就給淬火（特別是在線淬火）提出更高的要求：1、必需能夠提供足夠大的冷卻速度范圍，以滿足不同合金的淬火對(duì)冷卻速度敏感性的要求和不同型材壁厚對(duì)冷卻速度的要求；2、在保證足夠大的冷卻速度的同時(shí)有效減少型材冷卻時(shí)的變形，以保證型材的尺寸精度。

Summary:

In recent years, with the rapid development of economy, the increasing application of industrial aluminum profile results in higher demands, which are mainly in: 1. wider section  and more complicated shape; 2. more accurate dimensional tolerance; 3. higher mechanical properties. To meet the requirements of the market for aluminum products, the production process and equipment should be more demanding, especially online quenching process. Because to achieve high mechanical properties, ensure fixed supersaturated solid solution, and reserve the hardening precipitates, it demands for fast cooling rate. However, the faster the cooling rate, the greater the residual stress and residual deformation of the quenched profile. Thus the dimensional accuracy of the profile can not be guaranteed. Given above three elements, we claim that more emphasis should be put on quenching process (especially online quenching): 1. with a various range of cooling rate to be managed to meet the requirements of quenching sensitivity to cooling speed and wall thickness of different alloys; 2. with adequate cooling rate, the deformation of the profile after cooling is effectively reduced to ensure the dimension precision.

 

背景：鋁擠壓材在線淬火的現(xiàn)狀

Background: The actuality of quenching technology in extruded aluminium

經(jīng)過近十年的快速發(fā)展，鋁擠壓裝備已得到很大的提升，在線淬火的技術(shù)也得到很大的進(jìn)步，但仍然跟不上鋁型材產(chǎn)品發(fā)展的需要。

After nearly a decade of rapid development, machines including online quenching for aluminum extrusion has been greatly improved, yet it still can't answer to the development of aluminum products.

1、目前國內(nèi)在用的傳統(tǒng)在線淬火大部分都相對(duì)較落后

Most of the conventional online quenching in China is relatively backward

1）未能提供足夠大的冷卻速度范圍，不能根據(jù)不同合金和型材壁厚來選擇不同的冷卻速度；

Failure to provide adequate cooling rate to meet the requirement of different alloys and wall thickness

2）調(diào)節(jié)性差。型材截面往往都是不對(duì)稱的，壁厚也不是均勻的，如果不能根據(jù)型材截面的情況進(jìn)行冷卻速度大小的調(diào)節(jié)，厚壁的地方就會(huì)冷卻的慢，薄壁的地方就會(huì)冷卻的快，這樣就會(huì)造成型材變形和性能不均；

Short of regulatory. With asymmetrical structure and uneven wall thickness, if the cooling rate can not be adjusted as per the section shape, it will cause deformation and unstable performance, for instance, thick-walled shapes often are cooled slowly, whereas thin-walled shapes are cooled quickly.

3）操作性差。有些在線淬火裝置具備了以上兩點(diǎn)的功能，但操作性差，工人實(shí)際操作困難，精確度差，且耗時(shí)，所以根本無法滿足使用的需求。

Difficult to operate. Some online quenching devices have the above mentioned functions, but the workers have difficulty in actual operation with poor accuracy and high time consumption, so there is no way to compete the demand of use.
由于以上的原因，造成型材變形量大，性能不穩(wěn)定，廢品率過高，成本上升，難以滿足生產(chǎn)的需求。所以提升國內(nèi)在線淬火的裝備水平，已是國內(nèi)鋁型材裝備行業(yè)的重要任務(wù)。

In view of large deformation, unreliable performance, high waste rate, and high cost, we conclude that it is critical for the domestic aluminum equipment industry to improve the online quenching equipment.

2、目前歐美日本等發(fā)達(dá)國家的在線淬火裝置相對(duì)比較先進(jìn)

Online quenching devices in developed countries such as Europe, America and Japan are relatively advanced

1）風(fēng)冷、霧冷、高壓噴水聯(lián)合一起，能提供較大的冷卻速度范圍，使用時(shí)可根據(jù)不同的合金、不同的型材截面來選擇合適的冷卻方式。如6063合金型材可選擇風(fēng)冷，厚壁6061合金型材可選擇高壓噴水，而薄壁的6061合金型材則可選擇霧冷；

It is a combination of air, mist and water cooling to provide a wide cooling range, so as to adopt proper cooling mode as per needs, like air cooling can be applied to 6063 alloy, high pressure spray can be applied to thick-walled 6061 alloy, and mist cooling can be applied to thin-walled 6061 alloy.

2）調(diào)節(jié)性較好。一種是在型材截面的周向上分布若干路風(fēng)口和噴頭，每一路風(fēng)口和噴頭均可調(diào)節(jié)，這樣就可根據(jù)型材截面結(jié)構(gòu)不同進(jìn)行冷卻強(qiáng)度的方向性調(diào)節(jié)。如壁厚較厚的一側(cè)需要較強(qiáng)的冷卻強(qiáng)度，壁厚較薄的一側(cè)則需要較弱的冷卻強(qiáng)度。這樣有利于型材整體冷卻均勻，在保證足夠冷卻速度的前提下，減少型材的變形；另外一種是多段冷卻，每一段可選擇不同的冷卻速度。由于淬火開始階段變形較敏感，如果一開始就采用較快的冷卻速度，而型材截面的周向上又不能進(jìn)行方向性的調(diào)節(jié)，就會(huì)造成型材變形量大。故淬火前段可選擇相對(duì)緩慢的冷卻速度，先將型材緩慢冷卻到一定的溫度后，后段再采用較快的冷卻速度進(jìn)行急冷。這樣既可保證足夠的冷卻強(qiáng)度，同時(shí)也能減少型材的變形。

Good regulatory. 1. The nozzles are distributed around the section with independently adjustable columns, which makes it possible to apply proper cooling rate to achieve optimal mechanical properties and correct dimensional tolerances. 2. Multi section cooling with independently adjustable sections. Due to the initial rate of quenching process dictates the initial metal hardness. Some shapes will warp if cooled too quickly. Therefore, a mild cooling rate is preferred at the initial of quenching process. When the profile is slowly cooled down to a certain temperature, then a fast cooling rate is allowed. Thus ensures adequate cooling intensity and small deformation.

3）操作性較好。所有的這些調(diào)節(jié)均可通過人機(jī)界面進(jìn)行控制，調(diào)節(jié)比較方便，操作性強(qiáng)?？刂葡到y(tǒng)有自動(dòng)記憶功能，將每次生產(chǎn)的工藝參數(shù)自動(dòng)記錄下來，下次使用時(shí)可自動(dòng)調(diào)用。

Easy to operate. All these adjustments can be managed on man-machine interface, which is convenient and operable. The control system has automatic memory function, which automatically records the process parameters of each production and can be automatically recalled when produce the same profile.

但是，因?yàn)殇X型材擠壓是間歇擠壓，非擠壓時(shí)停頓在淬火區(qū)段的型材與擠壓時(shí)通過淬火區(qū)的型材受到的有效冷卻時(shí)間不一致，這樣會(huì)引起該兩段的淬火強(qiáng)度不一致、性能和變形量也不一致。這個(gè)問題國際上比較先進(jìn)的淬火裝置也沒有很好解決。

However, the extrusion process is intermittent. The effective cooling time of the profile in dead cycle is different from that in extrusion cycle, which will cause unbalanced quenching intensity, performance, and deformation. This problem also exists in the international advanced quenching devices.

 

論文正文：國內(nèi)新的在線精密淬火技術(shù)及裝置的介紹

Main thesis: Introduction of new online precise quenching technology and equipment in China

1、 在線精密淬火因素考慮

Factors
1-1 足夠的冷卻速度范圍

Adequate cooling range

只有足夠的冷卻速度，才能確保過飽和固溶體被固定下來不分解，防止強(qiáng)化相析出，才能保證型材淬火時(shí)效后的力學(xué)性能達(dá)到最佳水平。要達(dá)到足夠的冷卻速度，就要配置合理的冷卻源、冷卻長(zhǎng)度以及冷卻密度。冷卻源就是指風(fēng)機(jī)、水泵以及相應(yīng)的冷卻介質(zhì)。冷卻長(zhǎng)度就是指風(fēng)口、噴管或水槽的長(zhǎng)度。冷卻密度就是指風(fēng)口或噴頭的分布密度。而這三方面都要根據(jù)該生產(chǎn)線所生產(chǎn)型材的最大線密度、不同合金的淬火對(duì)冷卻速度敏感性強(qiáng)弱以及擠壓出材的速度綜合計(jì)算來確定。所生產(chǎn)的型材線密度越大、合金的淬火對(duì)冷卻速度敏感性越強(qiáng)、擠出速度越快，所要配置的風(fēng)機(jī)和水泵越大，淬火區(qū)的長(zhǎng)度就要越長(zhǎng)，用水作介質(zhì)的水溫就要越低。當(dāng)?shù)蜏氐乃紳M足不了冷卻速度的情況下，還可以在水中加入不同的溶劑來調(diào)節(jié)水的冷卻能力。比如聚乙醇，通過調(diào)節(jié)聚乙醇水溶液的濃度來控制冷卻速度。

To ensure fixed supersaturated solid solution and optimum mechanical properties, and reserve the hardening precipitates, it requires adequate cooling rate. As a result, a reasonable cooling source, cooling length and cooling density are claimed. Cooling source refers to the fan, water pump and cooling media. Cooling length refers to the length of air nozzle, spray nozzle, or water tank. Cooling density refers to the distribution density of the air nozzles or spray nozzles. The three elements are determined by the maximum linear density of the profile, the quenching sensitivity to the cooling speed and the extrusion speed. With bigger linear density, greater quenching sensitivity to the cooling speed, and faster extrusion speed, it needs bigger power of ventilator and water pump, longer quenching zone and cooler water temperature. When low temperature water can not meet the cooling rate, different solvents can be added to regulate the cooling capacity of water, such as, polyethanol is used to control the cooling rate by regulating the concentration of ethanol solution.

1-2 型材截面的冷卻速度保持基本一致

Consistent cooling speed
只有冷卻速度基本一致，才能確保型材淬火效果基本一致，從而保證型材性能的均勻性，有效減少型材的變形和彎扭。要保證型材截面周向的冷卻速度一致，就要保證截面周向冷卻強(qiáng)度能夠根據(jù)型材截面結(jié)構(gòu)情況、壁厚的厚薄進(jìn)行調(diào)節(jié)。比如壁厚較厚的一側(cè)需要冷卻強(qiáng)度高，壁厚較薄的一側(cè)則需要冷卻強(qiáng)度低些，這樣就可使得型材截面同一時(shí)間內(nèi)冷卻到相同的溫度。

To ensure uniform performance and less irregularity and bending, it requires consistent cooling rate. Thus, it is necessary to adjust the cooling intensity to section shape. For example, thick-walled shapes are cooled using a high cooling intensity, while thin-walled shapes are cooled using a lower cooling intensity, which allows the profiles to be cooled to the same temperature at the same time.

而要保證型材縱向的淬火強(qiáng)度一致，就要保證縱向上所受的冷卻時(shí)間一致，也就是縱向上每部分通過淬火區(qū)的有效冷卻時(shí)間一致。

It is necessary to ensure consistent cooling time so as to ensure balanced quenching intensity, that is, the effective cooling time of each section in quench zone is consistent.
1-3 適應(yīng)不同型材截面寬高比的變化

Proper ratio change of width to height
特別中大型擠壓機(jī)所生產(chǎn)的型材截面寬高比變化非常大，當(dāng)生產(chǎn)板材時(shí)，寬高比可能達(dá)到100:1以上，而生產(chǎn)管材或棒材時(shí)，寬高比可能是1:1。在這么大的寬高比變化情況下，如何保證型材上下左右各個(gè)表面與風(fēng)口和噴頭之間的距離合適，從而保證有效的冷卻速度和減少能耗。

The ratio change of width to height, particularly for large extrusion press, is great. When produce aluminum sheet, the ratio is more than 100:1, while produce aluminum tube or billet, the ratio may be 1:1. Under this circumstance, we need to manage adequate gap between nozzles of four sides to ensure effective cooling rate and reduce energy consumption.
1-4 操作性比較強(qiáng)，能方便操作人員進(jìn)行調(diào)節(jié)控制。

High automation and easy operation.
1-5 在滿足以上四點(diǎn)的前提下，如何有效降低運(yùn)行的成本。

Lower cost.

2、兩種新的在線淬火裝置

Two new online quenching devices
為解決以上的問題，我們?cè)O(shè)計(jì)了兩種不同形式的在線淬火裝置。一種是針對(duì)中大型（1650t以上）擠壓機(jī)配套的，另一種是針對(duì)中小型（1650t以下）擠壓機(jī)配套的。因?yàn)橹写笮蛿D壓機(jī)所生產(chǎn)的型材截面相對(duì)較大，比較容易實(shí)現(xiàn)型材上下左右四個(gè)方向冷卻差異化控制。而中小型擠壓機(jī)所生產(chǎn)的型材截面相對(duì)較小，實(shí)現(xiàn)型材上下左右四個(gè)方向冷卻差異化控制相對(duì)較難，所以要有針對(duì)性的設(shè)計(jì)不同的方案。

To solve the above problems, we designed two types of online quenching devices. One is for large extrusion press (above 1650T), and the other is for small extrusion press (below 1650T). Because for relatively large section produced by the large extrusion press, it is easy to realize the cooling differential control of the four sides of profile. While for relatively small profile section, it is relatively difficult to achieve the cooling differential control in the four sides of profile. Therefore, the design should be accordingly.

2-1 中大型擠壓機(jī)配套在線淬火裝置的功能特點(diǎn)

Functional features of online quenching device for large extrusion press
2-1-1 風(fēng)冷、風(fēng)霧混合、霧冷、高壓噴水四合一的功能

Combination of air, air & mist, mist, high pressure spray cooling
我們采用風(fēng)冷、風(fēng)霧混合、霧冷、高壓噴水四合一的功能，每一種功能都可以根據(jù)需要進(jìn)行大小調(diào)節(jié)，形成從弱到強(qiáng)無級(jí)變化的冷卻強(qiáng)度，適應(yīng)不同合金不同壁厚對(duì)冷卻強(qiáng)度的不同需求。比如一般生產(chǎn)薄壁的6063合金型材時(shí)采用風(fēng)冷，生產(chǎn)厚壁6063合金型材或薄壁6061合金型材時(shí)采用風(fēng)霧混合，生產(chǎn)中薄壁6061合金時(shí)采用霧冷，生產(chǎn)厚壁6061合金型材時(shí)采用高壓噴水。

We use the combination of air, air and mist, mist, high pressure spray cooling, and each function can be adjusted as per requirement. The cooling intensity is adjustable for different wall thickness and different alloys. For instance, thin-walled 6063 alloy uses air cooling, thick-walled 6063 alloy or thin-walled 6061 alloy uses air and mist cooling, medium and thin-walled 6061 alloy uses mist cooling, thick-walled 6061 alloy uses high pressure spray.

冷卻源的配置，要根據(jù)該機(jī)臺(tái)生產(chǎn)的型材米重、擠出速度、合金淬火對(duì)冷卻速度敏感性強(qiáng)弱等因素來決定。型材米重越大、擠出速度越高、合金淬火對(duì)冷卻速度敏感性越強(qiáng)，風(fēng)機(jī)和水泵的功率就越大、淬火區(qū)的長(zhǎng)度也就越長(zhǎng)。

The capacity of the cooling source is determined by those factors such as the ratio of weight to length, extrusion speed and quenching sensitivity to cooling speed. With higher ratio of weight to length, higher extrusion speed and greater quenching sensitivity to cooling speed, it requires bigger power of the ventilator and water pump, and longer quenching zone.

為什么要采用風(fēng)霧混合？主要因?yàn)閿D壓車間的氣溫比較高，純風(fēng)冷時(shí)，哪怕風(fēng)壓、風(fēng)量很大，冷卻速度也不高，并且能耗很大。如果直接用霧冷或水冷，相對(duì)部分合金型材的冷卻速度又過高，型材容易變形。而用風(fēng)霧混合，既能獲得比風(fēng)冷強(qiáng)很多的冷卻效果，又能降低風(fēng)機(jī)的能耗，從而獲得合適的冷卻速度。

The main reason of using air and mist combined cooling is that the environment temperature in the extrusion workshop is higher. When using air cooling only, even with high air pressure and big air volume, fast cooling rate cannot be attained and energy is costly. When using mist cooling or spray cooling only, the cooling rate of thin-walled shapes is relatively high and deformation is easily caused. When using air and mist combined cooling, the better cooling effect can be achieved and the energy is saved.

2-1-2 周向多路冷卻布置并冷卻強(qiáng)度差異化調(diào)節(jié)

Distribution of columns and differential adjustment of cooling intensity

 圖1 fig 1

為了解決截面周向冷卻的均勻性，圍繞擠壓機(jī)中心線平行分布若干路風(fēng)口和噴頭（如圖1所示），具體多少路要根據(jù)具體生產(chǎn)線所生產(chǎn)的型材截面寬度來確定。每一路風(fēng)口和噴頭都可單獨(dú)調(diào)節(jié)風(fēng)量或水量，以滿足不同合金和壁厚所需要的冷卻速度，確保截面上各個(gè)位置淬火均勻。這對(duì)確保型材性能均勻和有效減少型材變形起到關(guān)鍵作用。

In order to attain uniform cooling of the section, the nozzles should be distributed in parallel columns around the center line of the extrusion press (see fig 1). The quantity of columns is determined by the actual width of the section. Each column can be managed separately as per specific requirements to ensure balanced quenching, uniform performance and less deformation.

2-1-3 縱向分段調(diào)節(jié)及順序啟閉功能

Sectional adjustment and switch on/off in sequence

 圖2 fig 2

縱向的每段冷卻強(qiáng)度可以單獨(dú)調(diào)節(jié)。當(dāng)個(gè)別型材淬火時(shí)特別容易變形的，光用以上兩種功能還無法滿足時(shí)，還可以將縱向的前段冷卻強(qiáng)度調(diào)小，后段的冷卻強(qiáng)度調(diào)大。這樣既可保證型材得到充分的冷卻，又可以減少型材變形。

The cooling intensity of each section can be adjusted independently. When some shapes are particularly easy to bend during quenching, while the above two functions are not capable, you can reduce the cooling intensity of the front section, and increase the cooling intensity of the rear section to ensure adequate cooling and less deformation.

為了解決型材縱向淬火的一致性，各路風(fēng)口和噴頭在縱向上分若干段（如圖2所示），具體多少段要根據(jù)具體生產(chǎn)線需要來確定。每段都有獨(dú)立的控制閥來控制。換棒停止擠壓時(shí)，從冷床往擠壓機(jī)方向按順序分段關(guān)閉；換棒開始擠壓時(shí)，從擠壓機(jī)往冷床方向按順序分段開啟。這樣就可以使得型材縱向的冷卻時(shí)間基本一致，從而確保型材縱向的性能比較均勻，減少縱向的彎扭。

For the sake of obtaining balanced quenching, the nozzles should be divided into sections (see fig 2). Each section has an independent control valve. During the dead cycle, the section is switched off in sequence as the direction from handling table to extrusion press. During the extrusion cycle, the section is switched on in sequence reversely. In this way, the cooling time is basically consistent, thus to ensure uniform performance and small bending.

2-1-4 頂部風(fēng)口（噴頭）與側(cè)風(fēng)口（噴頭）上下位移調(diào)節(jié)

Adjustment of movement of air nozzles (spray nozzles) on top, left and right

 

 

圖3  風(fēng)門和兩側(cè)風(fēng)口上下錯(cuò)位調(diào)節(jié)

Fig 3 Adjustment of movement of air valves and air nozzles on left and right

為了解決型材寬高比變化過大，引起上下左右風(fēng)口或噴頭與型材表面之間距離變化過大，我們將上部的風(fēng)口和噴頭與左右的側(cè)風(fēng)口和側(cè)噴頭設(shè)計(jì)成分離的，并且相互間可以移動(dòng)（如圖3所示）。這樣就可以根據(jù)型材的寬高比來調(diào)節(jié)風(fēng)口或噴頭與型材表面之間的距離，確保上下左右各路風(fēng)口和噴頭與型材各表面保持合適的距離和位置，提高冷卻的精準(zhǔn)度和減少能耗的損失。

Due to big ratio change of width to height, the distance between nozzles and profile surface is changeable. If the nozzles on top are designed independently and moveable (see fig 3), the distance between nozzles and profile surface can be adjusted properly according to the specific ratio to improve precision and save energy.

 

2-1-5 輔助牽引頭

Subsidiary puller head

    

圖4  輔助牽引頭

Fig 4 Subsidiary puller head

在淬火作業(yè)中，牽引機(jī)一般不適宜進(jìn)入淬火區(qū)，特別是水冷作業(yè)。如果牽引機(jī)進(jìn)入淬火區(qū)，淬火裝置就難以正常工作，通過淬火區(qū)的這段型材就無法得到正常的淬火，將會(huì)造成該段型材的浪費(fèi)。在牽引機(jī)不進(jìn)入淬火區(qū)，而又能實(shí)現(xiàn)牽引和淬火同時(shí)進(jìn)行，就采用輔助牽引頭（圖4所示）。當(dāng)生產(chǎn)第一根鑄棒時(shí)，用輔助牽引頭牽引著型材，用牽引機(jī)牽引著輔助牽引頭，并且淬火裝置正常工作。

During quenching operation, especially water-cooling operation, the puller is not allowed to enter the quenching zone. If the puller enters the quenching area, the quenching device will not work properly and the desired hardness will not be well obtained, which will cause the waste of the section. As the puller does not need to enter the quenching zone, and the traction can be done simultaneously, the subsidiary puller head (see fig 4) is adopted. When produce the first billet, the subsidiary puller head moved by the puller is used to pull the profile outside of the quenching zone.

2-1-6 人機(jī)界面控制及參數(shù)記憶功能

Man-machine interface control and data memory function

                 

圖5  人機(jī)界面控制及參數(shù)記憶功能

Fig 5 Man-machine interface control and data memory function

為了方便操作人員的控制，在線淬火裝置所有的動(dòng)作和工藝參數(shù)均可通過人機(jī)對(duì)話來進(jìn)行控制，友好的操作界面（圖5所示）非常適合國內(nèi)工人使用。為了提高調(diào)節(jié)的效率，減少因調(diào)節(jié)過程不當(dāng)所產(chǎn)生的廢品，控制系統(tǒng)特別設(shè)計(jì)了自動(dòng)記憶功能。每次生產(chǎn)的型材，當(dāng)認(rèn)為淬火的工藝參數(shù)比較合理時(shí)，可啟用記憶功能將該組參數(shù)記憶下來，下次再生產(chǎn)該型材時(shí)，只要錄入該型材的型號(hào)代碼，系統(tǒng)會(huì)自動(dòng)調(diào)用上次記憶下來的參數(shù)進(jìn)行生產(chǎn)。

To facilitate the control of operators, all online quenching device and process parameters are controlled by man-machine interface, which is simple and convenient (see fig 5). In order to improve the efficiency and reduce the waste generated by improper adjustment process, the control system is designed with automatic memory function. For each production, the quenching process parameters can be saved. When produce the same profile, inputting the alloy code, the system will automatically recall relative parameters.

 

 

2-1-7 遠(yuǎn)程調(diào)試、監(jiān)控和維護(hù)

Remote debugging, monitoring and maintenance
為方便調(diào)試、監(jiān)控和維護(hù)，控制系統(tǒng)設(shè)有遠(yuǎn)程監(jiān)控接口。有需要時(shí)，可通過網(wǎng)絡(luò)對(duì)系統(tǒng)進(jìn)行遠(yuǎn)程調(diào)試、監(jiān)控和維護(hù)。

The control system has remote monitoring interface to facilitate debugging, monitoring and maintenance. When necessary, the remote debugging, monitoring and maintenance can be conducted via internet.
以上方案在廣東豪美鋁業(yè)的2500t和3600t擠壓機(jī)所配置的在線淬火裝置（圖6所示）上得到充分的驗(yàn)證，完全可以滿足生產(chǎn)工藝的要求。型材經(jīng)過在線淬火和人工時(shí)效后，完全滿足力學(xué)性能的要求，而尺寸精度也得到充分的保證。

These functions have been applied to the online quenching device for 2500T and 3600T extrusion line in Guangdong Haomei Aluminum Industry (see fig 6). After quenching and artificial aging, the mechanical properties and the dimension precision of profile are guaranteed.

圖6  工程實(shí)例

Fig 6 Quenching device in Guangdong Haomei Aluminum Industry

 

2-2 中小型擠壓機(jī)配套在線淬火裝置的功能特點(diǎn)

Functional features of online quenching devices for small extrusion press

針對(duì)中小型擠壓機(jī)配套配套的在線淬火裝置，除了中大型擠壓機(jī)配套的在線淬火裝置上a、b、c、f、g的功能配置基礎(chǔ)上，加強(qiáng)以下的功能（如圖7所示）：

Apart from above mentioned functions (under clause a, b, c, f, g) for large extrusion press, the following functions of online quenching devices for small extrusion press are put (see fig 7)

圖7  噴頭的可旋轉(zhuǎn)及擺動(dòng)控制

Fig 7 Rotation and swing of the nozzles

2-2-1 噴頭設(shè)計(jì)成可以擺動(dòng)和旋轉(zhuǎn)

The nozzles are designed to swing and rotate.
為解決小型材截面上噴水的準(zhǔn)確定位，將噴水和噴霧的噴頭設(shè)計(jì)成可以擺動(dòng)和旋轉(zhuǎn)的，如圖示中的α和β。噴頭旋轉(zhuǎn)一定的角度，可以將噴射出的水和霧的寬窄進(jìn)行一定范圍的調(diào)節(jié)，甚至可調(diào)成平行于擠壓中心線的一條線，這樣就能將水集中到型材的某一局部上。噴頭擺動(dòng)一定的角度，也是有利于將水和霧對(duì)準(zhǔn)型材的某一位置。

To achieve accurate positioning of water spray onto the small section, the spray nozzles of water and mist are designed to swing and rotate (shown as α and β in fig 7). It is to adjust the rotating angle or swing angle to adjust the spray width, even align with the center line of the extrusion press, so water and mist are amassed to a certain shape of the profile.
2-2-2 噴頭還可以進(jìn)行徑向移動(dòng)

The nozzles are designed to move in radial direction.
噴頭還可以進(jìn)行徑向移動(dòng)一定的距離，這也是為了更好的進(jìn)行冷卻定位，減少水的壓力損失。該方案在深圳福晟五金制品有限公司的1450t和1800t的擠壓機(jī)所配置的在線淬火裝置上得到充分的驗(yàn)證。型材經(jīng)過在線淬火和人工時(shí)效后，完全滿足力學(xué)性能的要求，而且尺寸精度也得到充分的保證。

The nozzles can move a certain distance in radial direction, which is for better cooling positioning and lower loss of water pressure. The design has been applied to the online quenching equipment for 1450T and 1800T extrusion line in Shenzhen Fusheng Hardware Products Co., Ltd.
 
總結(jié)：在線淬火的研發(fā)方向

Conclusion: Further development of online quenching
1、往智能化控制方向發(fā)展

Intelligent control
目前，在線淬火裝置主要還是靠人來控制，靠操作人員根據(jù)不同的合金成分、不同的型材截面和壁厚情況來選擇不同的冷卻方式和冷卻速度。這樣不但會(huì)對(duì)人的依賴性強(qiáng)，而且影響效率和準(zhǔn)確性。所以應(yīng)往智能化方向發(fā)展，只要將產(chǎn)品的合金牌號(hào)和截面圖輸入控制系統(tǒng)，控制系統(tǒng)就會(huì)自動(dòng)選擇相應(yīng)的冷卻方式和冷卻速度。

At present, online quenching device is controlled by men. Operators select proper cooling mode and cooling rate based on alloy composition, cross section and wall thickness. Nevertheless, this will not only affect dependence on man, but also affect efficiency and accuracy. Therefore, the intelligent control should be developed. To input the alloy code and cross-section diagram into the control system, the control system will automatically select the corresponding cooling mode and cooling speed.
2、將目前需要離線淬火的部分合金能實(shí)現(xiàn)在線淬火

Convert offline quenching into online quenching
因離線淬火需要二次加熱，能耗比較高，如何將目前需要離線淬火的部分合金能實(shí)現(xiàn)在線淬火。那將大幅減少能耗，提高效率。

Because offline quenching requires secondary heating and high energy consumption, it is a must to convert offline quenching into online quenching to significantly reduce energy consumption and improve efficiency.

注釋：

Remark:

① 佛山市南海賽福鋁材設(shè)備有限公司已于2012年04月25日獲準(zhǔn)冠省名廣東賽福鋁材設(shè)備有限公司

“Foshan Nanhai Save Aluminium Equipment Co., Ltd.” obtained the name of “Guangdong Save Aluminium Equipment Co., Ltd” on Apr 25, 2012.

 

參考文獻(xiàn):

王祝堂，田榮璋  《鋁合金及其加工手冊(cè)》  中南大學(xué)出版社（第三版），2005.

Reference:

Mr. Zhutang Wang , Mr. Rongzhang Tian  Aluminium Alloy and Its Processing Manual  Zhongnan University Press (The 3^rd Edition)  2005