China Aluminum Industry Network: 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, which work together to ensure precise temperature regulation inside the furnace. The drive control system consists of programmable logic controllers (PLCs), variable frequency drives (VFDs), motor starters, and signal interfaces, enabling control over the soaking furnace, cooling chamber, induced draft fan, cooling fan, combustion air fan, exhaust fan, circulating fan, and the three-dimensional material trolley. There are a total of three cabinets, one operating panel, and one console located at the site, each assigned specific functions such as the PLC cabinet, drive cabinet, burner operation box, and stocker console.
The temperature control system operates by using 12 burners, divided into three zones, with each zone equipped with a smart controller to monitor and regulate the temperature. The host computer records the real-time temperature curve for each zone. Before starting the heating process, it's essential to check that the cooling water and compressed air supply are functioning properly. The temperature control instruments should be set to zero before ignition, and once the burners are successfully lit, the output can be increased accordingly. After ignition, the set points can be adjusted based on the required process parameters.
To start the system, first, close the control power circuit breakers in both the PLC cabinet and the drive cabinet, along with the VFD circuit breakers. Then, turn on the power switches for the heating exhaust fan, combustion air blower, cooling smoke fan, cooling blower, heating furnace door, and cooling furnace door. Once all power sources are activated, the indicators on the PLC and drive cabinets should light up. The three circulation fans will start in low speed, and when the temperature reaches the lower limit (set to 300°C), the PLC will switch them to high speed. If the temperature drops below 300°C or if the door is opened, the fans will automatically revert to low speed.
The material trolley control system manages the movement of the charging car, including the opening and closing of the heating and cooling chamber doors. The charging car has both manual and automatic modes, and the operator can switch between them using the hand/auto button. In manual mode, the furnace door can be closed, loosened, or retracted step by step. Similarly, the cooling chamber door can be controlled manually. The trolley has an automatic positioning function, allowing it to move between stations autonomously. It must always start and return from its initial position, following a strict sequence for loading and unloading materials.
Interlock protection and alarm systems are in place to ensure safe operation. These include low cooling water pressure, low combustion air pressure, low gas pressure, furnace door misalignment, trolley displacement, VFD failure, burner faults, and high furnace pressure alarms. Certain operations, like igniting the burners, cannot proceed unless all interlocks are satisfied. For example, the gas solenoid valve cannot open unless the circulation fan is running, and the furnace door cannot be raised unless it is in the loose position.
After prolonged downtime, the equipment must undergo insulation testing before being used again. Only when the electrical insulation meets the required standards can the system be restarted. Following these procedures is crucial to prevent accidents and ensure the safe and efficient operation of the entire system.
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