I. Basic Model Definition
• RCM: Muffle-equipped controlled atmosphere mesh belt resistance furnace
• 180: Rated total heating power of the furnace body: 180kW
• 9: The furnace chamber is divided into 9 independent temperature-controlled heating zones (2 preheating zones + 5 high-temperature heating zones + 2 slow cooling zones)
• Rated furnace temperature: 950℃ (quenching/carburizing/carbonitriding)
• Effective furnace chamber dimensions: 700 (width) × 4800 (total heating length) × 90 (material height) mm
• Mesh belt width: 500mm, capacity approximately 300kg/h (direct quenching), 160kg/h (carburizing)
II. Control Cabinet Input Power Parameters
1. Main Heating Power Supply
o Specification: Three-phase five-wire AC380V, 50Hz, ±10%
o Total rated current: ≈322A
o Incoming circuit breaker: 400A molded case circuit breaker (with leakage/overload protection)
2. Control circuit power supply
o AC220V: Instruments, touch screen, contactor, solenoid valve, fan
o DC24V: PLC, sensor, limit switch, alarm light, frequency converter signal
o Matching switching power supply: 300W/24V industrial DC power supply
3. Auxiliary power circuit
o Independent 380V circuit for belt frequency converter, circulating fan, cooling water pump, and cleaning machine motor
III. Core configuration of the 9-zone temperature control system (core of the control cabinet)
1. Temperature control hardware parameters
• Zone: 9 independent closed-loop PID temperature control (independent adjustment of zones 1 to 9)
• Temperature control instruments: 9 intelligent programmable PID temperature controllers (0 to 1200℃)
o Input: K Type 1 Thermocouple Compensating Lead
o Output: 4～20mA/0–10V Regulated Signal Driven SSR
o Temperature Control Accuracy: ±1.5℃, Furnace Temperature Uniformity ≤±5℃
o Functions: Segmented Temperature Rise Curve, Over-Temperature Alarm, Thermocouple Breakage Detection, Self-Tuning PID
• Power Regulation Element: 9 sets of single-phase solid-state relays (40A/220V), contactless continuous power regulation 0～100% output
• Over-Temperature Safety Redundancy: Independent mechanical over-temperature controller for each zone (cuts off the main heating circuit at 1000℃, hard interlock)
2. Heating Power Distribution (180kW evenly distributed across 9 zones)
• Rated Heating Power per Zone: 20kW/zone
• Heating Element: 2 silicon carbide rods/ceramic heating plates per zone, single-phase 220V power supply
IV. Belt Drive Frequency Conversion Control Parameters
1. Frequency Converter Specifications: 3.7kW Three-phase vector frequency converter (380V input)
2. Speed range: 0.5～50Hz, corresponding to belt speed 17.5～200mm/min continuously adjustable
3. Control method: Touch screen 485 communication speed control + panel manual potentiometer dual mode
4. Protection functions: Overload, overcurrent, stall, belt jamming alarm, shutdown interlock
5. Speed feedback: Encoder pulse acquisition, real-time display of belt running speed on the screen
V. PLC main control system parameters (whole machine logic control)
1. PLC host: Domestic / Mitsubishi FX3U standard type
o DI digital input: 32 points (emergency stop, furnace door limit, water pressure, thermocouple failure, frequency converter fault, low air pressure, material level)
o DO digital output: 32 points (heating in each zone, belt, fan, atmosphere solenoid valve, alarm buzzer, indicator light)
2. Human-machine interface: 10-inch industrial touch screen
o Functions: Real-time temperature curves for 9 zones, historical curve storage (30 days), storage of 99 sets of process formulas, fault records, parameter access control (operator/administrator)
o Communication: RS485 networking with PLC, frequency converter, and temperature control instruments
3. Interlocking Logic (built-in forced protection in the control cabinet)
o No water pressure (<0.15MPa): Heating prohibited, automatic shut-off of heating output
o Furnace door not closed properly: Heating and atmosphere valves locked and prohibited from opening
o Any zone thermocouple failure: Audible and visual alarm, heating in that zone stopped
o Over-temperature >960℃: Total furnace heating shut-off
o Mesh belt overload jamming: Heating + atmosphere synchronous shutdown
VI. Atmosphere Gas Circuit Control Module (integrated in the control cabinet)
1. Controlled objects: Nitrogen, methanol, propane/cracking gas solenoid valves
2. Output circuit: DC24V intermediate relay drives each gas circuit valve
3. Pressure detection: Low-pressure switch (furnace protection gas pressure <50Pa alarm shutdown)
4. Safety Logic: When the furnace temperature is <760℃, the flammable atmosphere valve is forcibly locked and cannot be opened to prevent explosion.
VII. Control Cabinet and Panel Component Parameters
1. Cabinet Mechanical Parameters
• Dimensions: Height 1800 × Width 1000 × Depth 450mm, cold-rolled steel plate with powder coating
• Protection Rating: IP54, bottom dustproof, top cooling fan
• Environmental Operating Conditions: 0～55℃, environment without corrosive gases or dust
2. Panel Component List
1. Main power switch, 9-way heating branch switch, frequency converter/auxiliary circuit breaker
2. 9 PID temperature controllers, voltmeter, ammeter, water pressure gauge, atmosphere pressure gauge
3. 10-inch touch screen, mode switching knob (manual/automatic)
4. Independent buttons: conveyor belt start/stop, fan start/stop, atmosphere manual switch, alarm reset
5. Indicator lights: power, heating operation in each zone, conveyor belt operation, fault alarm, water pressure normal
6. Red mushroom-shaped emergency stop button: Pressing this button cuts off all heating, transmission, and atmosphere outputs.
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