Wuxi Wondery Industry Equipment Co., Ltd

I. Equipment Overview & Functional Description This Plate-Fin Heat Exchanger Core Assembly Machine (Model: Core Assembly Machine 1200) is specifically engineered for the manual stacking and high-efficiency structural assembly of heat exchanger cores. During workshop operation, the stacked core is compressed vertically under a heavy load by two top-mounted pneumatic-hydraulic booster cylinders. This setup delivers a powerful clamping force ranging from 0 to 5 Tons (5T) that is continuously adjustable without steps, while the horizontal span of both cylinders can be modified laterally to match various core lengths. The overall external dimensions of the machine are approximately 2500 (L) $times$ 700 (W) $times$ 2600 (H) mm. Its compact and heavy-duty structural frame is optimized to support and match a targeted effective core size of $Phi1000 times 1000 times 160text{ mm}$, demonstrating premium operational adaptiveness. Through comprehensive automated pneumatic-hydraulic fastening, the system guarantees rigid geometric accuracy for the finalized plate-fin heat exchanger. The finished product verticality is tightly controlled within $pm0.6text{ mm}$; furthermore, when the core profile fits within $le 1200 times 1100text{ mm}$, the diagonal tolerance requirement is strictly locked under $< 2text{ mm}$, effectively eradicating potential brazing faults caused by misalignment. Once compressed and squared, operators can seamlessly install tension tie rods or utilize a strapping machine to wrap and secure steel bands. The pressure is then released, and the mechanical sliding table moves the completed workpiece outward by approximately 260 mm for easy crane lifting and extraction. The entire sequencing loop is conveniently handled via push-buttons, which minimizes the cycle time per batch while providing complete operational safety when handling heavy workloads. II. Flexible Processing Range & Core Technical Parameters To accommodate multi-specification customization for varied heat exchanger cores, the mechanical structures and drive strokes are engineered with large adjustable parameters. The machine features the following flexible assembly capacities: Effective Core Length Adjustable Range: Supports a wide spectrum from 300 to 1200 mm, easily accommodating the length positioning of small, medium, and large plate-fin heat exchangers. Effective Core Height Adjustable Range: Covers a vertical range from 0 to 1100 mm, where the self-adaptive vertical stroke provides ample working clearance for dense, multi-layered fin configurations. Effective Core Thickness Adjustable Range: Accommodates thicknesses from 30 to 200 mm, ensuring both slim cooling modules and deep industrial-grade core units are precisely centered and firmly clamped. III. Equipment Power Supply & Utility Requirements To ensure the assembly machine achieves long-term, uninterrupted, and stable operation under demanding manufacturing environments, all control blocks and pneumatic components are chosen based on severe workshop standards: Operational Cycle: All structural elements and power units are rated under heavy-duty deterioration constraints, fully satisfying continuous industrial 24/7 operation profiles. Operating Power Supply: Standard configuration runs on single-phase AC 220V, 50Hz (allowing smooth operational thresholds within voltage fluctuations of $pm10%$). Ambient Temperature Range: All electrical controls and sealing compounds exhibit high environmental durability, supporting regular line production from $-10^{circ}text{C}$ to $70^{circ}text{C}$. Pneumatic Supply Line: The client must provide a reliable workshop compressed air feed maintaining a gas source pressure of 0.4–0.7 MPa with a rated flow volume of at least 30 L/min. IV. Core Equipment Configurations & Hardware Architecture 1. Drive & Clamping Mechanism Design Fixture Power Motor: Driven by a high-torque stepper motor system, ensuring stable starting torque along with precise mechanical travel limit constraints. Movement Travel Speed: The horizontal movement velocity of the clamping fixture is fully adjustable by the operator from 0 to 30 meters per minute, balancing transit efficiency with alignment safety. Pressure Compressing Block: Equipped with 2 top-mounted heavy-duty pneumatic-hydraulic booster cylinders. Compared to pure pneumatic units, they provide superior pressure stability, and they remain much cleaner and oil-free compared to conventional hydraulic stations. Sliding Ejection Platform: Upon finishing the core strapping cycle, the mechanical sliding table extends outward by approximately 260 mm, freeing the workpiece entirely from the upper structure and allowing unhindered overhead crane access. 2. Critical Pneumatic & Electrical Spare Parts Solenoid Directional Valve: Industrial-grade Model 4V-310C-10 (1 Set), offering quick response times and low internal leakage. Intermediate Safety Relay: Renowned brand Model RXM2AB2BD DC24V (1 Set), securing a long lifecycle for control logic responses. V. On-Site Production Operational Process Flow System Initialization: Power on the central electrical switchboard, open the main compressed air valve, and adjust the system to the designated working pressure required by the product recipe. Dimension Setup: Calibrate and adjust the mechanical positioning of the side clamping plates to mirror the footprint of the incoming core batch. Manual Stacking Sequence: Lay down the bottom tooling fixture plate, then layer the cover plates, bar seals, and cooling fins sequentially until the core reaches its stacked target height. Alignment Clamping: Once stacking is complete, center and place the upper tooling fixture plate directly on top of the stacked core assembly. Pre-Pressing & Squaring: Actuate the upper and lower pre-press buttons to compress the stack vertically. Stop to manually adjust and square up both side faces of the core to guarantee a neat stack. Final Compressive Lock: Once squaring is verified, trigger the primary pressure button to lock the core tightly at its fully designated clamping load (0-5T). Secure the core permanently using the pull-rod fixture method or thread steel bands using an integrated strapping machine. Ejection & Cycle Reset: Release the pneumatic-hydraulic pressure, actuate the sliding platform to roll the completed core out of the workstation for crane removal, reset the mechanisms, and prepare for the next assembly run.

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.