Wuxi Wondery Industry Equipment Co., Ltd

I. Industry Insight: Strict Demands for Temperature Uniformity and Automated Transfer in Heavy-Duty Shell Hardening In the manufacturing chain of high-strength mechanical components and heavy structural sectors for national defense industries (such as heavy steel workpieces with 155mm configurations), optimizing the comprehensive mechanical properties—achieving an ideal sorbite microstructure that blends high tensile strength with premium impact toughness—requires rigorous quenching and high-temperature tempering (Toughtening/Sorbite treatment). Due to the substantial unit weight and high stacking density of these profiles (with a batch capacity reaching 6 tons), thermal processing faces two critical engineering bottlenecks: Extreme Thermal Gradients across Zones: During the $950^{circ}text{C}$ high-temperature quenching and $650^{circ}text{C}$ tempering stages, any volatile temperature variance inside the working zone will cause non-uniform microstructural transformations, directly ruining hardness tolerances and impact durability. Transfer Speed and Operational Hazards: The transfer duration from the time the furnace door unlatches until the 6-ton workload is completely submerged into the quenching medium must be minimized. Relying on traditional manual crane lifting for such heavy, glowing components fails to hit the required narrow "golden window" and poses intense thermal radiation safety hazards to workshop operators. WONDERY’s 3D Forklift Type Fully Automatic Heat Treatment Production Line represents a definitive solution to these high-tonnage batch continuous handling challenges. Moving away from standard mesh belt or walking-beam lines limited by weight capacities, this system utilizes a flexible cluster layout consisting of: 1 unit of 3D Intelligent 无轨 Forklift + 1 unit of Full-Fiber Quenching Furnace + 2 units of Full-Fiber Tempering Furnaces + 1 unit of Pneumatic Tilting Quenching Tank + Fixed Loading/Unloading Stations. Utilizing heavy-duty heat-resistant alloy material frames, the system implements completely automated, unmanned, "one-button smart-controlled" material routing across multiple furnace installations and liquid medium chilling stations. Referencing the engineering standards outlined in the document "155mm Shells Automatic Heat Treatment Production Line.docx", WONDERY engineered and successfully executed this complete intelligent heat treatment facility featuring a combined rating of $450text{ kW}$ (Model: WDL260630UKR). II. Technical Solutions and Full-Line Process Architecture 1. Detailed Description of Core Equipment Units Full-Fiber Box Quenching Furnace (1 Set): Features an effective chamber volume measuring 1.6m Depth $times$ 1.7m Width $times$ 1.2m Height, with a rated batch loading capacity of $6text{ tons}$. The lining architecture is composed entirely of high-purity aluminum silicate refractory ceramic fiber block modules anchored by stainless steel structural links, successfully eliminating thermal short-circuiting and heat absorption losses found in brick linings. Heating elements utilize premium 0Cr27Al7Mo2 high-temperature resistance bands hung securely via high-frequency ceramic supports on both side walls and the rear wall. The configuration is divided into 3 independent temperature control zones with a combined rating of $180text{ kW}$. Dual Setup Full-Fiber Box Tempering Furnaces (2 Sets): Because tempering holding times are traditionally longer than quenching heating durations in standard sorbite heat treatment cycles, WONDERY configured 2 units of matching chamber dimensions ($1.6times1.7times1.2text{ m}$). These furnaces carry a maximum operating rating of $650^{circ}text{C}$ with a power distribution of $120text{ kW}$ per unit (totaling $240text{ kW}$). To ensure rapid convection thermal distribution during lower-temperature processing, the roof of each tempering furnace incorporates a long-axis centrifugal circulation fan linked with a $3text{ mm}$ thick SUS304 stainless steel internal air deflector shell, maintaining a tight furnace temperature uniformity of $le pm5^{circ}text{C}$. Intelligent 3D Motorized Material Forklift (1 Set Trackless Vehicle): Operating as the central mechanical transit engine of the plant, this automated forklift features a heavy-duty structural steel welded frame capable of forward/backward transit, left/right lateral shifting, upward/downward hoisting, and 3D fork manipulation. The safe operational payload capacity is rated at $ge 6000text{ kg}$. Guided by precise photoelectric distance encoders and track limit positioning, it shifts smoothly with an alignment tolerance within $pm2text{ mm}$. Pneumatic Tilting Controlled Quenching Tank (1 Set): Engineered with large volumetric retention, the tank houses 2 units of $1.5text{ kW}$ axial-flow fluid agitators and a $22text{ kW}$ high-volume circulation heat exchanger pump network. It features an integrated pneumatic tilting platform inside the tank. Once the 3D forklift deposits the material basket onto the cradle, the system automatically triggers the medium flow. The total transit time from the quenching furnace door opening, forklift extraction, to full medium submersion is optimized within $le 45text{ seconds}$, securely locking in the desired supersaturated martensitic structure. 2. Schneider IPC + Siemens S7-1200 Digitalized Central Control Command Distributed Network Infrastructure: The low-level logic execution across the entire line relies on a centralized Siemens S7-1200 PLC processing unit. The furnaces, automated forklift, and quenching mechanism communicate continuously over an industrial Ethernet (Profinet) fieldbus linked directly back to the primary control console. Industrial Personal Computer (IPC) Centralization: The central control station houses a Schneider (or equivalent top-tier brand) heavy-duty Industrial Personal Computer (IPC) integrated with supervisory control software and real-time CCTV monitoring feeds. Operators can deploy complex multichannel thermal recipe profiles from the safety of the control room. The system displays, tracks, logs, and exports full time-temperature heating history, auto-generating Excel spreadsheets that conform to rigid global defense and industrial traceability standards. Precision Power Management & Control Resolution: Temperature control relies on large-screen intelligent digital PID program controllers working via heavy-duty three-phase thyristor power regulators (SCR) operating in a zero-crossing triggering profile. This ensures a control precision of $pm1^{circ}text{C}$ and completely prevents sudden electrical power spikes from affecting the local plant power grid. Full Life-Cycle Safety Grid & Protection: All low-voltage circuit breakers, contactors, and switchgears are selected from premium industrial brands such as CHINT or DELIXI, while the forklift drive integration employs high-performance Delta or ABB VFD inverters. The control logic embeds a rigorous failsafe multi-way interlocking loop managing furnace door status, forklift fork extension, frame proximity detection, and liquid agitation, along with an automated power-failure alarm network. The operator junction boxes comply with IP55 protection ratings. III. Commercial Parameters and Turnkey Shipping Specifications The complete engineering scope of this continuous automated 155mm shell heat treatment plant is offered at a total EXW valuation of $163,600.00 USD: (Breakdown: 3D Automatic Heavy Material Forklift: $62,100.00 USD; 6-Ton Box Quenching Furnace: $28,700.00 USD; Two Sets of 6-Ton Box Tempering Furnaces: $60,800.00 USD; IPC Centralized Control & Digital CCTV System: $12,000.00 USD) All primary structures support modular disassembly to facilitate standard containerized stuffing for international ocean transport. Backed by a comprehensive 15-month international warranty, an efficient 90-working-day lead time from down payment receipt, and complete packages of English schematics, foundation drawings, and technical installation guides, WONDERY guarantees precision thermal solutions for heavy-duty structural components worldwide.

I. Industry Insight: Solution Heat Treatment Bottlenecks for Aluminum Structural Components In high-precision manufacturing fields such as automotive lightweighting, aerospace, and rail transit, aluminum alloy die castings and plates are extensively used. To substantially enhance the mechanical strength, hardness, and corrosion resistance of aluminum components, they must undergo rigorous Solution Heat Treatment followed by rapid quenching. However, aluminum alloy solution processing poses two extremely strict engineering challenges: Extreme Temperature Uniformity: In the late soaking stage, the temperature variance throughout the furnace working zone must be kept minimal to prevent local over-burning or insufficient solutionization. Strict Quenching Transfer Window: Once heating and soaking are finalized, the components must be rapidly transferred and fully submerged from the high-temperature furnace chamber into the quenching medium within a golden window (typically less than 12 seconds) to lock in the required supersaturated solid solution phase. Conventional box furnaces or standard pit furnaces feature slow transfer mechanisms and large thermal losses, failing to meet high-grade alloy standards. Addressing the global high-end non-ferrous metal processing sector, WONDERY launched the intelligently controlled, rapid-discharge Vertical Aluminum Alloy Solution Furnace System ($varnothing1200 times 1500text{ mm}$) (Proposal No: WDL2606116NH) , achieving a premium international turnkey delivery at the facility of client GAL in India. II. Technical Solutions and Process Architecture 1. Detailed Description of Core Process Units Top Vertical Furnace Body Unit: The furnace working zone features an effective size of varnothing1500 times 1900 , enclosed by a240 high-density standard refractory ceramic fiber blanket insulation lining. This layout fully eliminates thermal bridging, containing the external shell temperature rise within ambient +$25^{circ}text{C}$. The heating elements utilize 0Cr25Al5 high-grade anti-oxidation resistance bands , evenly distributed across all four inner walls, secured via high-temperature ceramic screws , and wired in a Y-configuration across 2 independent temperature control zones. A top-mounted 5.5 6-pole powerful hot air circulation fan works in tandem with a  SUS304 stainless steel air deflector system to ensure the furnace temperature uniformity is strictly within text during thermal soaking, with a control accuracy under High-Speed Dual-Speed Hoisting Mechanism (1T Winch): The structural material frame is rated for a load capacity of le 1000 (basket dimensions of varnothing1200 times 1500. To balance stable suspension with extreme quenching transitions, WONDERY implemented a fast-lowering and slow-raising dual-speed winch profile : the rapid downward transfer velocity reaches $22text{ m/min}$. Paired with a pneumatic cylinder-actuated slide-open door that unlatches in just 4 seconds , the system guarantees a total elapsed time of from the initial furnace door opening to complete immersion in the quenching medium, delivering industry-leading performance that easily surpasses the 12-second threshold.   Multi-Dimensional Mobile Quenching Tank: Positioned directly beneath the elevated vertical furnace, the mobile quenching tank is driven by a motor reducer via a wheel-and-chain assembly , traveling smoothly into position at. Heavy-duty limit switches securely lock its travel boundaries. The tank is outfitted with a 60kW independent electrical heating system and a2.2 high-flow water circulation pump to break up any vapor blankets forming around the hot castings, ensuring an instantaneous and uniform thermal exchange. 2. Rittal-Standard Digitalized Control Cabinet System High-Precision Power Regulation: Each heating zone is managed by a Japanese Shimaden SRS13A high-precision intelligent program meter. These meters utilize three-phase SCR power regulators with zero-crossing triggering, preventing electrical spikes on the plant grid and yielding rapid data control feedback. HMI and Data Visualization: The core operation terminal employs a 10-inch Kunlun Tongtai high-resolution industrial touchscreen. This enables operators to program, monitor, record, and extract full heat treatment process curves , backed by user password access privileges.

I. Industry Insight: Strict Demands for Atmosphere Control and Temperature Uniformity in Precision Cold-Drawn Tubes In the manufacturing supply chains of automotive fuel pipes, hydraulic cylinders, and high-pressure boiler lines composed of precision cold-drawn steel tubes (such as SAE 1008/1010 grades), work hardening stands out as a critical roadblock affecting subsequent bending, flaring, and machining operations. To eliminate residual micro-stresses and reconstitute raw material ductility, the steel pipes must undergo a precise bright annealing or normalizing treatment at high temperatures up to $950^{circ}text{C}$. However, conventional open-atmosphere furnaces prompt extreme superficial oxidation and decarburization at such thermal levels, compromising dimensional tolerances and increasing surface roughness far beyond premium industrial delivery grades. WONDERY’s Support Roller Type Mesh Belt Bright Annealing Production Line represents the definitive engineering response to these thermal processing challenges. The system creates an air-tight, hermetically isolated thermal processing envelope filled with a cracked ammonia atmosphere ($text{H}_2text{ 75}% + text{N}_2text{ 25}%$) acting as a highly reducing protective barrier. By sustaining a structured 60-minute in-furnace transit time, the line guides the tube profiles through a strict "Heating-Holding-Dual Cooling" sequence under an oxygen-free envelope, ensuring the output tubes arrive at the unloading table completely clean, bright, and scales-free. Following the successful commissioning of heavy-duty vertical Vacuum Pressure Impregnation systems for industrial motor insulation (referenced in the document named "260602VPI1500-3000 Semi-auto Vacuum Impregnation Equipment System.docx"), WONDERY has once again asserted its core competency in industrial fluid heating and metallurgy by delivering this continuous line stretching a total length of 36,825 mm (Model: WDL260608BR). II. Technical Solutions and Full-Line Process Architecture 1. Continuous Modular Long-Axis Framework & Low-Stress Synchronous Drive Engineering To orchestrate the continuous feeding profile of long-axis seamless steel pipes ($L = 6000text{ mm}$, diameter $Phi14 sim 38.1text{ mm}$), WONDERY divided the 36.8-meter line into five structurally interdependent modules engineered for low tensile deformation: Front Loading Roller Conveyor: Features a heavy structural steel welded entry bed measuring $6000 times 900 times 1020text{ mm}$ driven by a $0.55text{ kW}$ variable frequency gear motor setup. This section leads to an integrated $2000text{ mm}$ stainless steel preheating connector containing a ceramic fiber curtain air-lock door and an automatic gas ignition system to isolate the internal reduction atmosphere from atmospheric air. Low-Tension Support Roller Drive (Proprietary Technology): Standard mesh belt lines running continuously at $950^{circ}text{C}$ subject the conveyor belt to high mechanical tension, leading to thermal creep and frequent tearing. WONDERY eliminates this vulnerability via a synchronous idler support design. High-temperature SUS310 alloy rollers support the mesh belt across the heating chamber, while the lower return rollers use a core-type design paired with high-temperature KF bearing assemblies and aluminum alloy heat sinks. The mesh belt ($SUS314, 400 times 49000 times 2.0/3.0text{ mm}$) serves primarily as a material carrier rather than a tension element, as sprockets and chains drive every idler roller in unison. This minimizes the operating tension on the belt, heavily extending its operational lifespan. 2. Four-Zone Independent Low-Voltage Radiant Heating & Anti-Decarburization Refractory Insulation Squirrel Cage Radiant Tube Configuration: The main heating chamber spans a longitudinal distance of $6000text{ mm}$ with an allocated heating capacity of $130text{ kW}$ divided into 4 independent temperature control zones. The furnace contains 36 horizontal radiant tube shells ($Phi124 times 1050text{ mm}$ made of seamless SUS310) enclosing heavy 0Cr25Al5 heating elements supported by corundum insulators. Low-Voltage Power Supply Safety Distribution: The radiant tubes are powered by safe, low secondary voltage ($42text{ V}$) via 4 dry-type step-down transformers (380V/42V) mounted directly to the furnace exterior. This parallel low-voltage configuration reduces electrical fatigue on the resistance wires and allows operators to isolate and service a single radiant tube assembly without halting the continuous operation of the line. Anti-Carburization Brickwork & Forced Atmosphere Convection: The internal refractory lining incorporates LBK26 anti-carburization bricks bonded with high-purity silica sol, backed by structural insulation board, calcium silicate sheeting, and multi-layer Luyang cera blankets for a total insulation profile thickness of $400text{ mm}$. The roof houses 4 forced-convection atmosphere mixing blowers ($0.75text{ kW}$ motors with SUS310 blades and NSK bearings), ensuring a longitudinal temperature uniformity of $pm6^{circ}text{C}$ and a cross-sectional accuracy of $pm3^{circ}text{C}$. 3. Cascade Open-Jacket Liquid Chilling & Fail-Safe Digital Control Integration Dual-Stage Cooling Chambers: Directly following the heating zone, a $700text{ mm}$ slow-cooling chamber brings temperatures down progressively to prevent unexpected phase transformations in sensitive steel alloys. The pipe then travels through a $9000text{ mm}$ water-cooled section split into multiple zones using an open, self-pressurizing reflux jacket (Zone 1 uses a SUS310 liner, Zone 2 uses a SUS321 liner). Supported by a $15,000text{ L/h}$ industrial recirculating water setup, the cooling sector drops the pipe unloading temperature to $le120^{circ}text{C}$ before it reaches the final $7000text{ mm}$ discharge roller conveyor. Top-Tier Industrial Digital Control Center: Automated logic throughout the line is orchestrated by a Mitsubishi PLC paired with a 14-inch MCGS digital touchscreen interface. Precise thermal monitoring is managed by 5 Honeywell DC1040 PID controllers coupled with Shimax solid-state relays for thyristor voltage regulation, achieving a control resolution of $pm1^{circ}text{C}$. Fail-Safe Safety Interlocks & Gas Purging: The entire low-voltage distribution architecture relies on integrated Siemens air switches, contactors, and circuit breakers. The control cabinet features an automated emergency safety interlock: if factory power is suddenly cut, the system isolates the cracked ammonia gas line and injects a $6text{ m}^3$ reserve of high-pressure nitrogen to purge the furnace chambers, preventing flame flashback or explosive mixtures. Production logs (including temperature curves, speeds, and faults) are exported to Excel and retained on a dedicated PC for 6 months.