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WO2020055370A2 - Fault detection system for a heat treatment process - Google Patents

Fault detection system for a heat treatment process Download PDF

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Publication number
WO2020055370A2
WO2020055370A2 PCT/TR2019/050739 TR2019050739W WO2020055370A2 WO 2020055370 A2 WO2020055370 A2 WO 2020055370A2 TR 2019050739 W TR2019050739 W TR 2019050739W WO 2020055370 A2 WO2020055370 A2 WO 2020055370A2
Authority
WO
WIPO (PCT)
Prior art keywords
sensor
measurement data
heat treatment
feature
itself
Prior art date
Application number
PCT/TR2019/050739
Other languages
French (fr)
Other versions
WO2020055370A3 (en
Inventor
Özgür Yavuz TOPÇUOĞLU
Halil Emre ÇUBUKLUSU
Ömer Burak ÇE
Ali Osman AVCI
Aytaç GÖREN
Osman KORKUT
Original Assignee
Cms Jant Ve Maki̇na Sanayi̇i̇ Anoni̇m Şi̇rketi̇
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Cms Jant Ve Maki̇na Sanayi̇i̇ Anoni̇m Şi̇rketi̇ filed Critical Cms Jant Ve Maki̇na Sanayi̇i̇ Anoni̇m Şi̇rketi̇
Publication of WO2020055370A2 publication Critical patent/WO2020055370A2/en
Publication of WO2020055370A3 publication Critical patent/WO2020055370A3/en

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
    • C21D9/34—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for tyres; for rims
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D11/00—Process control or regulation for heat treatments
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
    • C21D9/0006—Details, accessories not peculiar to any of the following furnaces
    • C21D9/0012—Rolls; Roll arrangements
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
    • C21D9/0056—Furnaces through which the charge is moved in a horizontal straight path
    • 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
    • F27B9/00—Furnaces through which the charge is moved mechanically, e.g. of tunnel type; Similar furnaces in which the charge moves by gravity
    • F27B9/14—Furnaces through which the charge is moved mechanically, e.g. of tunnel type; Similar furnaces in which the charge moves by gravity characterised by the path of the charge during treatment; characterised by the means by which the charge is moved during treatment
    • F27B9/20—Furnaces through which the charge is moved mechanically, e.g. of tunnel type; Similar furnaces in which the charge moves by gravity characterised by the path of the charge during treatment; characterised by the means by which the charge is moved during treatment the charge moving in a substantially straight path
    • F27B9/24—Furnaces through which the charge is moved mechanically, e.g. of tunnel type; Similar furnaces in which the charge moves by gravity characterised by the path of the charge during treatment; characterised by the means by which the charge is moved during treatment the charge moving in a substantially straight path being carried by a conveyor
    • F27B9/2407—Furnaces through which the charge is moved mechanically, e.g. of tunnel type; Similar furnaces in which the charge moves by gravity characterised by the path of the charge during treatment; characterised by the means by which the charge is moved during treatment the charge moving in a substantially straight path being carried by a conveyor the conveyor being constituted by rollers (roller hearth furnace)
    • 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
    • F27B9/00—Furnaces through which the charge is moved mechanically, e.g. of tunnel type; Similar furnaces in which the charge moves by gravity
    • F27B9/30—Details, accessories or equipment specially adapted for furnaces of these types
    • F27B9/40—Arrangements of controlling or monitoring devices
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • 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
    • F27D19/00—Arrangements of controlling devices
    • F27D2019/0028—Regulation
    • F27D2019/0059—Regulation involving the control of the conveyor movement, e.g. speed or sequences

Definitions

  • the invention is about a fault detection for the roller type furnaces used in aluminum wheel production line
  • Aluminum is one of the widely used material in wheel production and low pressure die casting is generally used method.
  • T6 heat treatment is for getting the mechanical properties enhanced.
  • wheels are solutionised for 200-300 minutes at 510-550 °C and quenched at 75-85 °C, then artificial aging takes place at 140-160 °C about 160-180 minutes
  • the wheel heat treatment furnace is composed of big roliins conveyors in which there are hundreds of rolls that work together with the same speed to move the wheels inside. When the wheels are moving inside the heat treatment furnace any mechanical problem on the drive train (wedge break, gear stripping etc.) can lead to big cost.
  • the invention is a fault detection system which overcomes the state of the art for the heat treatment process of the rims that eliminates the disadvantages and provides additional advantages.
  • the purpose of the invention is to detect and give information to the operator about a possible fault and place on the rolling conveyor of heat treatment furnace.
  • Another object of the invention is to provide a new failure detection system by controlling the rotational speeds of the rollers moving the wheels, audibly or visually alerting the operator that the rotational speeds are out of the predetermined tolerance range.
  • Another object of the invention is to provide a new diagnostic system in which all data measured by the sensors can be monitored instantly, notified to the operator and stored.
  • the present invention provides a fault detection system for failures in roller conveyor type heat treatment furnaces located in the rim production facilities, which provide heat treatment to the rims, which enables the transport of the rims with the number of rollers therein that is composed of stations consisting of roll groups of variable numbers according to demand and furnace size, each station has sensor units positioned on the first row roll, said sensor units being configured to perform a revolution interval, ambient temperature and humidity measurement and Includes analysis unit that compares measurement data from sensor units with predetermined tolerance values and transfers all measurement data to the operator display and includes an operator display, whereby all measurement data can be displayed, which warns the operator in a visual and audible manner, out of tolerance measurements for stations.
  • Another aspect of this invention is including sensors that measures revolution interval of the each roll.
  • Another aspect of this invention is including sensors that measures humidity in medium which is located inside the each roll.
  • Another aspect of this invention is including sensors that measures temperature which is located inside the each roll.
  • the sensor unit comprises a battery whose charge is continuously transferred to the operator display, providing the energy required for the operation of the sensor unit.
  • Figure-1 Representative view of the diagnostic system of invention.
  • FIG. 1 Representative view of the sensor unit of the present invention.
  • diagnostic system (100) according to the invention is illustrated by way of example only, for a better understanding of the subject matter, which will have no limiting effect.
  • the disclosure describes a system for detecting failures in roller conveyor heat treatment furnaces (1 ) in the rim (12) production facilities,
  • the heat treatment process of the rims (12) is carried out in furnaces containing a number of stations (10) and roller (1 1) groups which transfer the wheels (12) from the inlet section to the outlet section. Hundreds of rollers (1 1) transfer hundreds of rims (12) in the furnace (1) are heat treated simultaneously.
  • Figure 1 is a representative view of the diagnostic system (100) according to the invention.
  • the fault detection system (100) consists of a sensor unit (20) which measures the rollers (11) revolution speed, the humidity and temperature values of the furnace (1), the display (40) indicating the data from the analysis units (30) and the data storage units (50) where the analysed data is stored.
  • Heat treatment furnaces (1 ) include a large number of rollers (11) for transporting wheels (about 1600). Positioning one sensor per roller (1 1) increases the cost considerably. Therefore, the rollers (1 1 ) are grouped and stations (10) are formed and one sensor unit is positioned in each station (10). In the stations in the figure, there are eight rolls (1 1). This number can be less or more depending on the need, there is no limitation introduced. No. Thanks to this sensor unit (20), the station (10) on which the failure is occurred and displayed on the operator screen (40) and the maintenance team is directed to the relevant station (10).
  • FIG. 2 is a representative view showing the internal elements of the sensor unit (20) used in the invention.
  • the sensor unit (20) consists of a motion sensor (21 ) that measures the revolution interval of the rolls (1 1), a humidity sensor (22) that measures ambient humidity, and a temperature sensor (23) that measures ambient temperature.
  • a battery (24) inside the sensor unit (20) which provides the energy required for the operation of the unit.
  • the battery voltage (24) in the sensor unit (20) is instantly notified to the operator display (40) and thus action is taken before the battery (24) of the sensor unit (20) has reached to a critical level.
  • the operating principle of the diagnostic system (100) is as follows; In the sensor unit (20) located on the first-row roller of each station (10), one full revolution interval of the roll (1 1), the humidity and temperature values of the station (10) , and the battery (24) percentage data are regularly measured. The measured values are sent to the analysis unit (30). It is evaluated whether the values measured in the analysis unit (30) are within the predetermined tolerance ranges and the performed analysis is transmitted to the operator screen. If the measured values at the stations (10) are out of tolerance, the operator is warned audibly and visually via the operator display (40). On the operator display (40), however, the data of all stations (10) can be viewed actively even within the tolerance range. Future maintenance and repair plans can be made right after detected those approaches tolerance limits. Analyzes (30) are recorded in a storage unit.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Thermal Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • General Engineering & Computer Science (AREA)
  • Heat Treatments In General, Especially Conveying And Cooling (AREA)
  • Tunnel Furnaces (AREA)
  • Waste-Gas Treatment And Other Accessory Devices For Furnaces (AREA)

Abstract

The invention (12) is a fault detection system (100) for detecting faults occurring in the heat treatment furnaces in the aluminum passenger car wheel production facilities. Which provides the (12) transport of the rims with a large number of (11) rolls. The invention has variable number of sensors that can be specified depending on the size of the furnace. The sensors (20) are located on the first (10) roll of each separately driven section of rolls (11). Mentioned sensors measure medium temperature, humidity, and revolutions per minute and send information to an analysis unit (30) that compares measurement data from sensor units (20) with predetermined tolerance values and transfers all measurement data to operator display (40), and getting characterized by including operator screen (40) that displayed about measured values which are out of tolerance.

Description

Fault Detection System for a Heat Treatment Process
Technological Aspect:
The invention is about a fault detection for the roller type furnaces used in aluminum wheel production line
State Of The Art:
Aluminum is one of the widely used material in wheel production and low pressure die casting is generally used method. Right after the casting process, T6 heat treatment is for getting the mechanical properties enhanced. lnT6 process, wheels are solutionised for 200-300 minutes at 510-550 °C and quenched at 75-85 °C, then artificial aging takes place at 140-160 °C about 160-180 minutes The wheel heat treatment furnace is composed of big roliins conveyors in which there are hundreds of rolls that work together with the same speed to move the wheels inside. When the wheels are moving inside the heat treatment furnace any mechanical problem on the drive train (wedge break, gear stripping etc.) can lead to big cost. The wheels get in contact while hot and moving; deformations and distortions occur and wheels become scrap for the recovery of such a fault the system should be cooled down the scrap wheels should be taken out and the conveyor system should be repaired accordingly. There is a serious loss of labor, time, energy, and capacity. On the search of literature, UA20120G14774 appeal numbered Ukraine patent document has been compared. That invention is about the heat treatment process that is applied on rims. However, it does not include a detection method for failures encountered during heat treatment.
Consequently, there is a need for a fault detection system for the heat treatment process of the wheels.
A Short Explanation of Invention:
The invention is a fault detection system which overcomes the state of the art for the heat treatment process of the rims that eliminates the disadvantages and provides additional advantages.
The purpose of the invention is to detect and give information to the operator about a possible fault and place on the rolling conveyor of heat treatment furnace. Another object of the invention is to provide a new failure detection system by controlling the rotational speeds of the rollers moving the wheels, audibly or visually alerting the operator that the rotational speeds are out of the predetermined tolerance range.
Another purpose of the invention is to provide a new fault detection system which measures and analyzes and reports to the operator the rotational speeds of the rollers carrying the wheels, the humidity and temperature of the environment during the heat treatment process. Another object of the invention is to provide a new fault detection system which helps the maintenance team to quickly rectify the fault by detecting at which station the possible faults occur and thus ensuring the continuity of the process.
Another object of the invention is to provide a new diagnostic system in which all data measured by the sensors can be monitored instantly, notified to the operator and stored.
In order to achieve all the objectives mentioned above and which will be emerged from the following detailed description, the present invention provides a fault detection system for failures in roller conveyor type heat treatment furnaces located in the rim production facilities, which provide heat treatment to the rims, which enables the transport of the rims with the number of rollers therein that is composed of stations consisting of roll groups of variable numbers according to demand and furnace size, each station has sensor units positioned on the first row roll, said sensor units being configured to perform a revolution interval, ambient temperature and humidity measurement and Includes analysis unit that compares measurement data from sensor units with predetermined tolerance values and transfers all measurement data to the operator display and includes an operator display, whereby all measurement data can be displayed, which warns the operator in a visual and audible manner, out of tolerance measurements for stations.
Another aspect of this invention is including sensors that measures revolution interval of the each roll.
Another aspect of this invention is including sensors that measures humidity in medium which is located inside the each roll.
Another aspect of this invention is including sensors that measures temperature which is located inside the each roll.
A further feature of the invention is that the sensor unit comprises a battery whose charge is continuously transferred to the operator display, providing the energy required for the operation of the sensor unit. Description of the Figures:
The invention will now be described with reference to the appended figures, so that the features of the invention will be more clearly understood. Rather, it is intended to encompass all alternatives, modifications and equivalents that may be included within the scope of the invention as defined by the appended claims. It should be understood that the details shown are only for the purpose of illustrating preferred embodiments of the present invention and are provided to the most useful and easily understandable description of both the shaping of the methods and the rules and conceptual features of the invention. On these drawings;
Figure-1 Representative view of the diagnostic system of invention.
Figure-2 Representative view of the sensor unit of the present invention.
The figures which help to understand the present invention are numbered as indicated in the attached drawing and are given below with their names.
Explanation of References:
100. Diagnostic Detection System
I . Station
I I . Roll
12. Rim
20. Sensor Unit
21. Motion Sensor
22. Humidity Sensor
23. Temperature Sensor
24. Battery
30. Analysis Unit
40. Operator Display
50. Storage Unit Explanation of Invention:
In this detailed description, the diagnostic system (100) according to the invention is illustrated by way of example only, for a better understanding of the subject matter, which will have no limiting effect. The disclosure describes a system for detecting failures in roller conveyor heat treatment furnaces (1 ) in the rim (12) production facilities,
The heat treatment process of the rims (12) is carried out in furnaces containing a number of stations (10) and roller (1 1) groups which transfer the wheels (12) from the inlet section to the outlet section. Hundreds of rollers (1 1) transfer hundreds of rims (12) in the furnace (1) are heat treated simultaneously.
Figure 1 is a representative view of the diagnostic system (100) according to the invention. Accordingly, the fault detection system (100) consists of a sensor unit (20) which measures the rollers (11) revolution speed, the humidity and temperature values of the furnace (1), the display (40) indicating the data from the analysis units (30) and the data storage units (50) where the analysed data is stored.
Heat treatment furnaces (1 ) include a large number of rollers (11) for transporting wheels (about 1600). Positioning one sensor per roller (1 1) increases the cost considerably. Therefore, the rollers (1 1 ) are grouped and stations (10) are formed and one sensor unit is positioned in each station (10). In the stations in the figure, there are eight rolls (1 1). This number can be less or more depending on the need, there is no limitation introduced. No. Thanks to this sensor unit (20), the station (10) on which the failure is occurred and displayed on the operator screen (40) and the maintenance team is directed to the relevant station (10).
Figure 2 is a representative view showing the internal elements of the sensor unit (20) used in the invention. Accordingly, the sensor unit (20) consists of a motion sensor (21 ) that measures the revolution interval of the rolls (1 1), a humidity sensor (22) that measures ambient humidity, and a temperature sensor (23) that measures ambient temperature. In addition, there is a battery (24) inside the sensor unit (20) which provides the energy required for the operation of the unit. By means of three different sensors of the invention, all possible failures can be detected. While detecting faults caused by rollers (11) with motion sensor (21), insulation problems of heat treatment furnace wall corresponding to the related station with humidity (22) and temperature (23) sensor are detected and intervened. The battery voltage (24) in the sensor unit (20) is instantly notified to the operator display (40) and thus action is taken before the battery (24) of the sensor unit (20) has reached to a critical level. The operating principle of the diagnostic system (100) is as follows; In the sensor unit (20) located on the first-row roller of each station (10), one full revolution interval of the roll (1 1), the humidity and temperature values of the station (10) , and the battery (24) percentage data are regularly measured. The measured values are sent to the analysis unit (30). It is evaluated whether the values measured in the analysis unit (30) are within the predetermined tolerance ranges and the performed analysis is transmitted to the operator screen. If the measured values at the stations (10) are out of tolerance, the operator is warned audibly and visually via the operator display (40). On the operator display (40), however, the data of all stations (10) can be viewed actively even within the tolerance range. Future maintenance and repair plans can be made right after detected those approaches tolerance limits. Analyzes (30) are recorded in a storage unit.
With the invention, it is possible to determine which roller (1 1) group breakdown occurs in a furnace (1 ) which has an average of 1600 rolls (11) and to direct the maintenance teams there. In addition, thanks to the storage unit (50), the errors taking place in the stations (10) are stored and analyzed, frequency of the faults and possible faults are detected in advance and precautions can be taken before the failure takes place again. Thus, the continuity of the process is ensured by preventing damage and deformation to the wheels (12) transported in the furnace (1 ).

Claims

1-The invention is a fault detection system for detecting failures in the roller type heat treatment furnaces (1) in the rim (12) production facilities, which provides the transport of the wheels with a group of rolls (1 1). Features of invention are;
-to include a series of stations (10), consisting of rolls (1 1) of variable numbers according to demand and furnace (1) size
-having sensor units (20) positioned on the first row roll (11) of each station (10),
-the sensor units (20) which are configured to measure (11 ) revolution interval, ambient temperature, sensor battery voltage and humidity,
-includes an analysis unit (30) that compares the measurement data from the sensor unit (20) to the predetermined tolerance values and transfers all measurement data to the operator display (40),
-characterized in that it includes an operator display (40) that alerts the operator visually and audibly in the case of out of tolerance measurement detections of stations (10) and displays all measurement data,
2- It is a diagnostic system (100) according to claim 1 and the feature of itself is the storage unit (50) where the analysis and measurement data in the analysis unit (30) can be stored continuously.
3- It is a diagnostic system (100) according to claiml and the feature of itself is includes a motion sensor (21) that measures the revolution interval of the rollers (11 ) that is located on sensor unit (20).
4- It is a diagnostic system (100) according to claim 1 and the feature of itself is includes humidity sensor (22) that measures humidity around the station (10) where sensors are located on rollers (11) that linked to sensor unit.
5- - It is a diagnostic system (100) according to claiml and the feature of itself is includes temperature sensor (23) that measures temperature around the station (10) where sensors are located on rollers that linked to sensor unit (20).
6- It is a diagnostic system (100) according to claiml and the feature of itself is includes the battery (24) that ensure the supply of required energy to working of sensor unit (20), which its voltage is transferred to the operator display (40).
PCT/TR2019/050739 2018-09-13 2019-09-09 Fault detection system for a heat treatment process WO2020055370A2 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
TR201813189 2018-09-13
TR2018/13189 2018-09-13

Publications (2)

Publication Number Publication Date
WO2020055370A2 true WO2020055370A2 (en) 2020-03-19
WO2020055370A3 WO2020055370A3 (en) 2020-06-04

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/TR2019/050739 WO2020055370A2 (en) 2018-09-13 2019-09-09 Fault detection system for a heat treatment process

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Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA2081055C (en) * 1991-11-05 1999-12-21 John R. Eppeland Method and apparatus for heat treatment of metal parts utilizing infrared radiation
US6860271B2 (en) * 2000-05-17 2005-03-01 O.R. Solutions, Inc. Thermal treatment system and method for controlling the system to thermally treat sterile surgical liquid
EP2929252B1 (en) * 2012-12-04 2018-10-24 Stork genannt Wersborg, Ingo Haet treatment device with monitoring system

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