F1: What is a trolley heating furnace?
The trolley-type heating furnace is characterized by the fact that the furnace bottom is designed as a flexibly movable trolley. Before heating, the car will complete the charging work outside the furnace, and the heating elements are carefully placed on special horns. Subsequently, through an efficient traction mechanism, the loaded trolley is smoothly pulled into the furnace for heating. After the heating process is completed, the traction mechanism comes into play again to pull the trolley out of the furnace for unloading. At this point, a crane is usually used to lift the heated workpiece to the forging equipment for further processing. Because of its unique design and functions, the trolley-type heating furnace is often used in conjunction with large-tonnage free forging hammers and free forging hydraulic presses. It is especially suitable for heating large steel ingots and semi-finished forgings, thus playing an indispensable role in the field of heavy forging. .
F2: What are the characteristics of the trolley-type heating furnace?
The trolley-type heating furnace has a distinctive feature. The furnace bottom is designed as a movable trolley, which provides great convenience during the workpiece heating process. Before the workpiece is heated, the trolley is loaded outside the furnace. When heating is required, the trolley is pushed smoothly into the furnace through the traction mechanism. After the heating is completed, the trolley is also pulled out of the furnace by the traction mechanism for unloading. This design is not only easy to operate, but also particularly suitable for the heating needs of large and complex-shaped workpieces.
In addition, the furnace temperature of the trolley-type heating furnace can be precisely controlled according to process requirements to complete a complete heating cycle. Its heating process can be adjusted arbitrarily within a wide range, which enables it to meet a variety of different heating needs.
It is worth mentioning that the trolley-type heating furnace has extremely high adaptability to the workpieces to be heated. Within the effective loading range of the trolley, the workpiece is not restricted by geometry, size, weight, etc., which provides the possibility for its wide application in industrial production.
At the same time, the trolley-type heating furnace has a small temperature difference between the furnace temperature control and the temperature of the heated workpiece, which means that the heating process is more uniform and precise, helping to ensure the quality and performance of the workpiece.
However, trolley-type heating furnaces also have certain limitations. As a periodic heating furnace, it is usually used for intermittent operation, which results in relatively large heat storage loss. In addition, the large movable furnace door of the movable trolley is not easy to seal, which will cause a certain amount of heat loss when the trolley comes out of the oven, thus affecting the thermal efficiency. Despite this, trolley-type heating furnaces still occupy an important position in industrial production because of their unique advantages.
F3: Structure of trolley-type heating furnace
① Furnace structure
The furnace structure of the trolley furnace is quite precise and scientific, and it mainly consists of several parts. The first is the solid steel structure of the furnace body, which provides a stable support frame for the entire furnace. Secondly, the furnace body is carefully constructed of refractory materials. These materials can resist high temperature erosion and ensure that the furnace remains stable in a continuous high temperature environment. The furnace door is cleverly fixed on the steel structure, which not only ensures sealing but also facilitates operation. In order to achieve a good sealing effect between the furnace wall and the periphery of the trolley, a sealing mechanism is specially designed. The existence of this mechanism effectively reduces the loss of heat energy and improves the working efficiency of the furnace. The design of the entire furnace structure takes into account not only practicality, but also safety and durability, which is the key to the efficient and stable operation of the trolley furnace.
a. Brick furnace
The steel structure of the furnace body is cleverly designed into a closed shell composed of steel columns and steel plates welded. This structure can not only effectively prevent the deformation of the refractory masonry due to thermal expansion and contraction, but also ensure the airtightness of the masonry. properties to maintain a stable heating environment in the furnace.
The design of the brick furnace wall is equally exquisite. It is composed of refractory bricks on the inside of the furnace, insulating bricks on the outside and insulating refractory fiberboards. This composite structure not only provides excellent fire resistance, but also excels in thermal insulation, helping to reduce heat loss and improve energy efficiency.
The design of the stove top is also quite ingenious, using arched bricks, wedge bricks and straight bricks to form an elegant arch structure, which further enhances the stability of the furnace. Insulation materials are also carefully laid on the arched top to effectively reduce heat dissipation at the top of the furnace and ensure uniform and long-lasting temperature in the furnace.
In trolley furnaces, the burner arrangement has also been carefully considered. They are installed at the lower part of the furnace walls on both sides, and their position is similar to the elevation above the trolley. This design allows high-temperature gas to form a circulating air flow through the channel between the trolley surface and the pad iron, thereby achieving a more uniform heating effect. For billet heating trolley furnaces, in addition to the burners installed on the lower part of the furnace wall, additional burners are installed on the upper part of the furnace wall. The heat provided by these burners accounts for about 20% of the total heat supply, effectively supplementing the lower supply. Not enough heat. In order to prevent the flame from directly washing the workpiece and causing overheating, the upper burner is usually tilted upward by 15°, while the lower burner is usually tilted downward by 5°~10° or arranged horizontally. This design ensures the uniformity and safety of the heating process. .
b. Refractory fiber furnace
There are significant differences in design concepts and practical applications between refractory fiber furnaces and brick furnaces. First of all, the masonry of the refractory fiber furnace is thinner and lighter than the brick furnace wall, and its thermal insulation performance is also superior. This feature significantly improves the thermal insulation effect of the refractory fiber furnace.
Secondly, the design of the refractory fiber furnace roof is also quite unique. Since there is no need to build a vault to withstand the lateral thrust, there is no problem of expansion stress in the masonry. This advantage allows the furnace steel structure to be lightweight, further reducing the weight of the entire heating furnace and improving its portability and flexibility.
Furthermore, the lightness of the refractory fiber masonry also brings another benefit, that is, the furnace wall can be easily held up by the steel to achieve a suspended design. This structure not only makes the furnace wall more stable, but also improves the ventilation and heat dissipation conditions at the bottom of the trolley, effectively extending the service life of the trolley.
Finally, it is worth mentioning that the softness and elasticity of refractory fibers provide more possibilities for furnace structure. Using these characteristics, a variety of sealing mechanisms can be designed that are superior to traditional sand seals, thereby further improving the sealing performance and thermal efficiency of the heating furnace. These innovative designs make refractory fiber furnaces have broad application prospects in the field of modern industrial heating.
② Trolley and track
In the trolley-type furnace, the entry and exit of workpieces is realized by the trolley running smoothly on the track under the drag of the traction mechanism. This design not only improves work efficiency, but also ensures safe transportation of workpieces.
The trolley is a complex structural component, which is composed of refractory masonry, a solid frame and a flexible walking mechanism. The refractory masonry on the upper part of the trolley can withstand the high temperature environment in the furnace and the heavy load of the workpiece, ensuring the safety of the workpiece and the trolley itself during the heating process. The frame part, under the influence of the downward heat conduction of the refractory masonry, shows excellent strength and stiffness. This frame is usually made of a delicate combination of beams and longitudinal beams welded by section steel. The steel plates and frames laid on the beams facilitate the construction of refractory materials. In addition, the sealing knives installed on both sides of the frame are closely integrated with the furnace body during operation, forming an effective seal, thereby reducing the loss of heat energy.
The running mechanism is a key component installed on the frame longitudinal beam. Its form includes roller belts, wheels, etc. The specific form chosen is closely related to the traction mechanism. The design of this mechanism enables the trolley to move freely on the track and complete the task of entering and exiting workpieces stably and efficiently.
At the same time, the selection of the trolley track is also determined based on the form of the trolley's traveling mechanism. Wheel trolleys usually use a single track, while roller belt trolleys use a double track design. These rails are not only installed inside the furnace, but also extend outside the furnace so that the trolley can enter and exit smoothly. The tracks mostly use heavy rails and are installed on solid foundation sleepers to ensure the stability and safety of the trolley. It is particularly worth mentioning that the track in the furnace is a complete section, and the two rails are cleverly placed on the same sleeper and firmly fixed by M-plates. The sleepers outside the furnace are divided into two sections, each section supports a separate rail. This design not only ensures the stability of the track, but also facilitates installation and maintenance.
③Oven door
The furnace door design of the trolley furnace is quite elegant, and its tall and solid structure ensures the stability and sealing of the environment inside the furnace. The furnace door itself and the door frame are made of heat-resistant cast iron, which is precision machined to form a flat and tight sealing surface. On the inside of the furnace door, refractory fiber or lightweight bricks are used for fine masonry. This design not only enhances the fire resistance of the furnace door, but also effectively reduces its overall weight.
When the furnace door needs to be closed, a set of efficient pressing mechanisms will smoothly push the furnace door to the sealing surface and ensure that it is tightly pressed, thereby preventing the loss of heat in the furnace. When the furnace door needs to be opened, the mechanism will gently push the furnace door away from the sealing surface, and then lift the furnace door steadily through the elevator. This series of smooth and precise movements not only ensures the convenience of opening and closing the furnace door, but also reflects the ingenuity of the detailed design of the trolley furnace.
④ Flue structure
The flue design of the brick trolley furnace is usually quite clever. They are usually set at the lower part of the furnace walls on both sides. This layout helps the hot flue gas to be discharged smoothly. Multiple flues will be gathered into the main flue under the furnace track, forming an efficient T-shaped smoke exhaust structure. This structure can ensure that the flue gas in the furnace is discharged in time, thereby maintaining the stability of the furnace environment.
For trolley-type furnaces with refractory fiber linings, the choice of flue location is more flexible and is not restricted by masonry. Therefore, this type of furnace can adopt a lower exhaust structure, but more often it will adopt a flue structure in the form of an upper exhaust on the back wall, side wall or roof of the furnace. This design not only improves the smoke exhaust efficiency, but also helps reduce heat loss in the furnace, further improving the working efficiency of the furnace. Whether it is a brick trolley furnace or a refractory fiber lined trolley furnace, the design of its flue structure fully reflects the engineers' ingenuity and deep understanding of thermal performance.
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