LPG Cylinder Production Line Heat Treatment Furnace

Technical specification

I. Frequency heating principle:

Frequency heating is using frequency power to change 380V, 50Hz power current into the suitable frequency current by rectification and contravariant. Input this current into resonant tank composed by the heating furnace, to make the furnace coil produce alternating magnetic field, while the pre-heating metal material stay in the alternating magnetic field, the material will produce the alternating current and heating by itself, high hot efficiency and low energy consumption.

Feature:

Frequency induction heating power factor≥96%, has automatic impedance adjustment function, the performance of energy saving is obviously.

Power output is steady, heating temperature is easy to control, good consistency to improve the heating quality.

Good diathermancy, magnetic field has a good permeability to the metal workpiece, it's not heating conduction, so the temperature difference of workpiece movements is small and improve the products' quality.

Temperature measuring system closed-loop control heating power, the precision of temperature is high.

Automatic impedance adjustment and automatic frequency adjustment function, inspecting system impedance transformation caused by the cylinder from cool to hot during the whole heating process automatically. Adjusting the output parameter automatically and making the whole heating process stay in energy-efficient state, saving more power.
 

II. Heating process requirement:

9KG, 14KG LPG cylinder production line:

Workpiece size: 9KG, 14KG LPG cylinder

Heating temperature: 780 - 900°C (The heating temperature sets according to the technology demand, adjustable)

Mixed production line heating speed: 14 second/per cylinder

Productivity: 2000 pcs / 8 hours
 

III. User required equipment power calculation:

9KG, 14KG LPG cylinder production line:

Size: BPS-550 frequency power. GT-9, 14/550 name: 9KG, 14KG LPG cylinder frequency heat treatment furnace.

Power: 550KW
 

IV. Composition of cylinder heating treatment equipment:

1. BPS series frequency power: one set

Size: BPS-550

Rated power: 550KW

Shunt capacitor: one set (under the furnace)

Power factor: Full power state arrive more than 96%.
 

A. Advanced control system:

The frequency power uses intelligent control system, it is a new SCR generation control system designed by absorbing the advance frequency heating technology both Chinese and foreign and special requirement for cylinder. The intelligent control system uses line unit design, all working units have luminotrons to display working state, the calculation of control system is processing in the special CPU module. It is reliable, steady and easy to maintain.

B. Adjustable power output:

During the power of equipment is 0 - rated power can be adjusted continuously, increasing the power adjustment output function, the low power of 9KG cylinder operation can guarantee the best working state, to ensure the commutating voltage reach 500V, improve the heating efficiency and save the energy consumption.

C. Complete protection function:

Not only equip with over-voltage protection, over-current protection, voltage restriction, current restriction functions, but also the intelligent protection system has the reliable release circuit while using the over-voltage high voltage, improve the frequency power running steady greatly, and has the over-temperature alarm function of cooling water temperature.

D. Obviously energy saving:

Retain all original functions in the intelligent control system, The unique design of the regulating function of impedance in the working process of the equipment according to the furnace workpiece (charge) impedance changes during heating (the inherent characteristics of the workpiece, the burden is in the process of heating) the working parameter adjustment of inverter power supply, the working efficiency is the highest in the state, so the high efficiency, energy saving, time saving. Frequency power intelligent impedance adjustment function, intelligent protection function is the domestic unique technology

E. Reliable starting system:

Zero voltage sweep frequency starting mode without impact, and the impedance adjustment function in the intelligent control system, making the essence of starting ability of frequency power has been greatly improved.

F: Automatic testing frequency output:

Intelligent control system, testing the change of system inductance caused by the cylinder temperature changing during the heating process automatically, adjust the output parameter in real time, making the whole heating process stay in high efficiency state and saving energy.

G: Simple troubleshooting:

Digital intelligent control system has fault display function, easy to find the fault, you can find the fault of the intelligent system without inspecting the equipment. Easy to maintain.
 

2. Heating normalizing furnace

It is made up of rectangular copper tube, which is optimized by computer. Aluminum alloy and insulation support, strong, long life. It consists of preheating section, heating section and insulation section

A: Pre-heating furnace: 1 set; length*width*height: 450*700*700mm

It consists of a metal material bracket, an efficient refractory material and a heat insulating material, no energy consume and heavy. Using the heat energy spillover the furnace for pre-heating.

B.  Heating furnace: 3 sets (integrated design); length*width*height: 1350*700*700mm

Power: 550KW

Furnace voltage: 750V

Dimension (length*width*height): 1350*700*700mm

It is made up of rectangular copper tube, which is optimized by computer. Aluminum alloy and insulation support, strong, long life. Three sets heating furnace use integrated design, it can heat multiply cylinders at the same time. Compare with old type single cylinder heating furnace, the new design can still guarantee the heating time for each cylinder to ensure the heat treatment quality after shorting the heating time.

C. Heat holding furnace: 2 sets

Dimension: 1400*700*700

It has the advantages of high efficiency, good heat preservation effect and long service life, which is composed of a metal material bracket, an efficient refractory material and a heat insulating material. The heat holding furnace including two parts.

D: Cylinder feeding system:

Consists of structural steel, stainless steel, pneumatic cylinder, etc. After completing the cylinder into the furnace heating and heating into the holding furnace. The method of cylinder feeding into heating furnace is pushing by the feed mechanism equip with the heating equipment. At the same time the deed mechanism on the other end of the heating equipment pushing the annealing cylinder into cylinder unloading conveyor.

E: Operation control system:

Setting heating process (set heating time and heating temperature), automatically control heating temperature and propulsion system. The electric control system sends out the instruction to complete a series of actions, such as pushing the cylinder into the furnace, heating, measuring temperature, and unloading cylinder, to ensure the whole process working as the setting parameter. Process requirements set on the touch screen, pushing the cylinder into the furnace, heating, temperature, unloading cylinder of a series of actions by the PLC control. The heating process parameters of each cylinder are recorded in the touch screen, and the temperature recording data can be extracted through the U disk. It can print the heating process parameter of all cylinders or check some printed cylinders. It can be operated by the operation table printer or print by U disk. During working touch screen display setting heating temperature, cylinder temperature, display and record the maximum cylinder temperature. Display and record the number of heating cylinders. For the occasional unreasonable data can be modified later.

It can also be provided with a heating speed, so that the pushing mechanism can push out the cylinder according to the set speed.
 

3. Closed loop temperature control system:

It consists of Infrared temperature measurement signal sampling sensor, temperature control system, etc. Reliable, high precision, strong anti-interference ability.

Temperature measuring range: 50~1200°C

Precision: ±1%

During working the heating temperature is set according to the requirement of heating process. When the cylinder reaches the set temperature, the control system sends out the material pushing signal, and the pushing mechanism pushes out the cylinder which reaches the setting temperature to enter the heat holding furnace.

The infrared sensor is installed on the special bracket, equips with protective cover.

Feature:
 

A: When each cylinder is heated, it is in the monitoring of the heating temperature control system, the consistency is good, and the heating quality is ensured, and the energy loss caused by the failure of the heating and the defect of the product quality can be avoided.

B: Closed loop temperature control system, can prevent burning, waste, reduce power consumption.

C: Dual control of heating temperature and power, with over temperature automatic power regulation and over temperature shutdown protection function.

Control cabinet        
                                                                                     


Burner nozzle



 

Complete LPG gas cylinder production line

I. Machinery list:
 

II. Description for each equipment:

1. De-coil and punching machine for small round sheet cutting from big sheet(material preparing for shell)
Technical data:
Raw material specifications:
Plate Thickness:2-4mm    Width of plate:Max.1170mm 
ID of steel coil:450-800mm    OD of steel coil:Max.1800mm  Weight of steel coil:Max.25T
Coil blanking specification:Ø370-Ø615mm   Blanking period:12s/time including auxiliary time
 
Hydraulic machine technical data
Motor power:46KW      Norminal capacity:6300KN   Max.working pressure:25Mpa
Slide travel speed:120mm/s  
Working table size:2500mm(front+back)*1500mm(left*right)
Weight of decolier:12T   Weight of hydraulic press machine:23T

2.63ton hydraulic logo printing machine
 
3. Hydraulic press drawing the head
Press the round sheet into a shell with dies.
  
4. Automatic trimming machine
This machine is reliable, easy to operate.
Technical data
Motor power:5.5KW   Air pressure:0.6Mpa   Trimming time:20s   Weight of machine:1.5T
 
5. End dish necking machine
Technical data
Motor power:4.5-11kw  Air pressure:0.6Mpa  Thickness of plate:1-10mm  
Necking head diameter:150-1200mm Necking time:10-50s (adjustable)
Weight of machine:1.5-3T

6.Cleaning machine
Technical data
Motor power:1.5kw   Polishing motor power:1.5kw*2  Air pressure:0.6Mpa 
Polishing wheel feed range:0.2-20mm  Efficiency:180Pcs/hour  Weight of machine:1.2T
 
7.Hole punching machine
Punch the hole on head of the cylinder
Technical data
Motor power:5.5kw  Punching speed:180Pcs/hour  Weight of machine:1.5T
  
8.Valve Seat  Welding Machine
To complete the welding of valve seat ring joints. Ensure uniform forming, good appearance, weld penetration and weld width meets the technological requirements, the clamping is convenient. Using submerged arc welding technology, girth welding at one time
Technical data
Rated voltage:220V Motor power:0.25kw Air pressure:0.6Mpa
 
9.Bottom base welding machine
Complete cylinder base girth automatic welding. To ensure concentricity, uniform forming, good appearance, weld penetration and weld width meet the technological requirements, the clamping is convenient. CO2 gas shield welding process, complete in one time welding.
Technical data
Current:AC380V+N    Motor power:0.55kw   Air cylinder pressure:0.5-0.7Mpa
  
10.Protection enclosure welding machine
Complete cylinder base girth automatic welding. To ensure concentricity, uniform forming, good appearance, weld penetration and weld width meet the technological requirements, the clamping is convenient. CO2 gas shield welding process, complete in one time welding.
Technical data
Rated voltage:AC380V  Motor power:0.55kw  Air cylinder pressure:0.5-0.7Mpa 
  
11.Assembling Machine 
To assemble both halves of the cylinder together and get ready for welding
Technical data
Cylinder diameter:250mm     Air cylinder pressure:0.5-0.7Mpa
 
12.Circumferential Seam welding machine

Option NO.1:
Technical data
Voltage:AC380V+N  Motor power:0.55KW  Rotation speed:Max.10rpm/min (adjustable)  
Motor power:0.55kw
 
Option NO.2:
Technical data
This machine is applicated to automated MAG circumferential welding for LPG cylinder,fire extinguisher bottle,etc.
Welding Length:Max.1500mm   Ø:250-400mm   Thickness:2.5-6mm
This machine price include 1 set panasonic welding machine(Model:GL3-500A),1 set cooling water device,welding seam tracker.
Producing capacity:250 pcs/8 hrs

13. Gas car-bottom heat treating furnace machine
This furnace is designed to anneal LPG cylinders by applying flame from gas burner on the cylinders. It composes, burner, flaming chamber, smoke collector, rails, chain roller, exhaling system.
It feature includes, adjustable time, self-control thermometer, perfect heat treatment result and fire off pollution.
 
Technical data
Producing efficiency:75pcs/hr  Feeding type:Chain drive/cylinder feeding
Cleaning size:Ø320*700mm------Ø420*1250mm
Dimension:(L*W*H):12500*1390*1560mm   removable transport
 
14. Hydrostatic Testing Machine
The machine is special for steel cylinder of liquefied gas cylinders,applicable to manufacturers and testing station for wuthstand voltage test on cylinder.Irrigation,pressurization,pressure,maintaining centralized control and automatic pouring completed by using water pump,equipped with a water tank,water can be recycled.
Technical data:
Pneumatic pressure:0.6Mpa                    Motor power:3kw 
Hydrostatic test pressure:3.2Mpa             Weight:1.1T
 
15. Cylinder drying machine
The equipment is used for drying the bottle cylinder after water pressure test.
 
16. Shot Blasting Machine
Shot Blasting Machine for LPG Cylinder are predominantly used to clean LPG/CNC/GAS cylinder in a continuous through feed process, remove remains of casting sand and cores, rust, old paint, visible signs of welding, eliminate surface stress, improve the fatigue strength of the workpiece, increases workpiece film adhesion of the paint job, and ultimately achieve the aim of improving the quality of surface and internal, prepare for surface protection (coloring, enameling, galvanizing, etc.).
Technical data
Produing efficiency:80-120pcs/hr        Shot blasting machine:2 sets
Hoist motor power:2.2KW                    Total power:31.2KW  
Weight:16T                                           Workpiece size:Ø320mm*680mm
Machine dimension:(L*W):7885*2460mm

17. Spraying production line
The spraying producing line for U track,using electric or natural gas,fuel oil,coal heating,hot air circulation,the allocation of fixed automatic spray gun 4,manual gun 1.Spraying powder or paint on the steel cylinders apperance.The cylinder into the oven drying after spraying
Technical data
Working voltage:380V 50HZ      Air pressure:0.4-0.6Mpa 
Total power:15KW             Working efficiency:180Pcs/jr
 
18. Valve mounting machine
The equipment is suitable for the liquefied petroleum gas cylinder angle value installation and use,it absorbs the domestic and foreign advance technology,using electrical control,pneumatic clamping,torque adjustable device,when reaching a certain torque,and go to the specificed direction after the automatic shutdown.The machine operation and flexible,convenient and safe
Technical data
Motor power:2.2KW                           Motor speed:1400r/min 
Work spindle speed:15.5r/min            Working air pressure:0.5-0.6Mpa
Consumption per hour:1.14m3           Clamping cylinder stroke:120mm
Rotation speed ration:1:59                  Weight:0.9T

19. Leakage Air Test Machine
The device for cylinder do tightness test with,composed of a water tank,a lifting cylinder,a bottle feeding machine,electric control part and other parts,work a bottle feeding mechanism of automatic cylinder will send to be test station,a lifting cylinder will fall into the water.the operating personnel rotation observations of the cylinder is not leaking cylinder,after the test and the cylinder out of water,a loop end.This machine is reasonable in structure,simple operation and maintenance.
Technical data
Air pressure:0.6Mpa                    Testing air pressure:2.2Mpa  
Holding pressure time:60s            Weight:1.8T

III. Machinery picture:
 

Automatic circumferential welding machine


 

Shot blasting machine



Powder coating line


 

IV. Successful projects: