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:

1. 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.

2. 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.