China Aluminum Industry Network 1. Electrical Control System The electrical control system of the aluminum soaking furnace is divided into two main parts: the temperature control system and the drive control system. The temperature control system includes intelligent temperature controllers, combustion devices, burners, and thermocouples to ensure precise temperature regulation inside the furnace. The drive control system consists of programmable logic controllers (PLCs), frequency converters, motor starters, position sensors, and other components, allowing for the control of the soaking furnace, cooling chamber, induced draft fan, cooling fan, combustion fan, exhaust fan, circulation fan, and the three-dimensional material trolley. There are a total of 3 cabinets, one operating box, and one control table on-site, each assigned specific functions such as the PLC cabinet, drive cabinet, burner operation box, and stocker console. 2. Temperature Control System Operating Instructions The heating process is carried out using 12 burners, divided into 3 zones. Each zone has an intelligent controller that manages the temperature, with the host computer recording real-time temperature curves for all three zones. Before ignition, it's essential to ensure the temperature control setting is at 0°C to avoid any initial output. After successful ignition, the temperature controller can be adjusted according to the process requirements. It's also crucial to check the cooling water and compressed air supply before starting the heating process. Once all systems are confirmed operational, the three circulation fans, heating exhaust fan, combustion air blower, and cooling smoke fan can be started in sequence. The gas main valve solenoid valves will open automatically, followed by the ignition of each burner via the burner operation box. If a flameout occurs, the corresponding indicator light will illuminate, and a remote reset can be attempted once. If multiple resets fail, manual inspection is required. Once all 12 burners are ignited, the soaking furnace can proceed with heating. The three-zone fans operate at low or high speed, starting at low speed and switching to high speed when the temperature reaches 300°C. If the temperature drops below 300°C or the door is opened, the fan automatically reverts to low speed. 3. Material Car Transmission Control System Operating Instructions The material car controls the opening and closing of the heating and cooling chamber doors, as well as its own movement. Before starting, the main power circuit breaker in the drive cabinet must be closed, along with the control and cooling fan circuit breakers. The control power button on the material car console should be pressed to activate the system. If the "communication status" indicator flashes, it indicates successful PLC communication. Otherwise, manual operation is required. Heating and cooling chamber doors have both manual and automatic modes, with switches to toggle between them. Manual operations include opening and closing the furnace door, loosening, and retracting the door pin. The sequence for opening and closing the door must be strictly followed. The material car can move up and down, and it features automatic retrieval and discharge functions, along with station positioning capabilities. The material truck starts from the initial position and returns there after each operation. 4. Interlock Protection and Alarm System Various alarms are triggered if critical parameters fall outside safe limits, such as low cooling water pressure, low combustion air pressure, low gas pressure, furnace door misalignment, trolley displacement, frequency converter failure, or burner malfunction. These alarms alert staff through sound and light signals. Several interlocks prevent unsafe operations, such as not starting the circulation fan before opening the gas valve, or not allowing the furnace door to rise unless the door is in the correct position. 5. Safety and Maintenance After long periods of inactivity, the equipment must undergo insulation testing before being used again. Only when the electrical insulation meets specifications can it be safely operated. Adherence to these procedures is critical to avoid serious consequences. Following these guidelines ensures safe and efficient operation of the entire system.
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