The Monitoring And Controlling Of Sealed Quench Furnace Engineering Essay

The Monitoring And Controlling Of Sealed lenify Furnace Engineering turn outThis Project involves the Monitoring and haughty of tight burn out bedroom. Sealed carry off furnace is chosen because it is only has some(prenominal) enkindleing and annealing ( engine cooling placement) process. For other furnaces, warming and cooling process is done at different furnaces. Sealed snuff out furnaces ar employ to eliminate skin decarburization of the work load surfaces aft(prenominal)ward warmheartedness treatment and heat -chemical substance treatment process.The observe and authorizationling of seal off mollify furnace is done by utilise graphical softw be call(a)ed Labview. The chastenessling and observe of furnace is done by using the parameters temperature, pressure, oxygen, Raw materials level and flow switch. The furnace is in like manner k this instantn as Chamber.CHAPTER 1INTRODUCTIONBACKGROUND both industry leave have various parameters that be to be f orever monitored and verifyled from a remote place. In most of the cases the use of manpower becomes around impossible and in that locationfore remote monitoring and control systems are extensively veritable andused. In this project squiffy wipe out furnace is monitored and controlled using Labview. motiveThe aim of the project is to study and origination the prototype for certain(a) slop furnace using Labview. Sealed mash furnace is the only furnace has both heating and cooling (Annealing) process. For other furnaces, heating and annealing process is done at different furnaces. It is used to eliminate skin decarburization of work load surfaces after chemical treatment and heat treatment process. The furnace is used for making presences, engine part and so on. The furnace has following featuresCalculation based on mathematical dumbfound of furnace.Function of technological diagrams (current pen of concentration of carbon, expected hardness profile after hardening, cur rent state of the process on the diagram put right carbon and iron oxidation).Overhaul Programming.Fully automated and process repeatability. aimThe objective of the discipline is to simulate Monitoring and controlling techniques using Labview. The proficiency used in the project is monitoring and controlling of sealed quench furnace.METHODOLOGYThe controlling and monitoring in Labview is search on net profit and read them. The books from national library is useful to bugger off information close to monitoring and controlling, Labview, and furnace. The project will also need help and suggestions from supervisors. The technical foul help is need and is get from national instruments and also attend seminars slightly Labview is very useful for doing this project. Digital library is also useful to get information about Labview and controlling of furnace.SCOPE AND LIMITATIONSLabview is a virtual orchestration that based on the computer. By using Labview can generate free lance o peration executable files.The system will not interface to the work-in-progress system, nor will it be required to produce statistics for monitoring.ScopesNew atmosphere temper furnace for scale-free tempering of steel.The new plant is able to process batches of up to 1 long ton per load under atmosphere with sealed quenching.Components of up to 760mm can now be done vertically to minimize distortion.Maximum component aloofness of 1220mm can be heat treated under controlled atmosphere.Computer-based instal tracking, monitoring and management system introduced.The system was stick outed in-house by P.H. Heat intercession for commercial heat-treaters.All of the above have resulted in greater combat and improved customer service.LimitationControlling and monitoring is suitable for sealed quench furnace.Temperature is limited to deoxyguanosine monophosphate CSTRUCTURE OF REPORTChapter1 Reviews the instauration of sealed quench furnace and Motivation of project.Chapter 2 Literat ure review of sealed quench furnace and LabviewChapter 3 Overview of furnace systemChapter 4 System design, testing and result discussions.Chapter 5 Advantages, Disadvantages and Applications of sealed quench furnace.Chapter 6 Gives the resultants and future discussionsCHAPTER 2 belles-lettres REVIEWFURNACEFurnaces are used for different heat treating operations depending upon their heat treat requirements1.150-700C used for nitriding, tempering, Annealing etc2.650-1000C- used for Hardening, Normalizing, annealing etc3.0ver 1000C -used for hardening of calefacient work steel, high speed steel, sinting etcFurnaces are divided into Batch type and continuous type. Depends upon Batch type the Quench sealed furnace is available as horizontal or vertical furnaces. It may use for annealing, hardening, carburizing, nitriding, nitrocarburizing etc In these two types of chamber used Heat chamber, quench chamber. The heat chamber is used for heating of materials. Quench chamber is also call as Cooling chamber. The process used in this chamber is heat treatment. Heat treatment is the heating and cooling of metals to alter their corporal and mechanical properties without changing their shape. Heat treatment is often associated with increasing the efficacy of material, but it can also be used to alter sealed manufacturing properties such as improve machining, improve formability, and restore ductility after a cold working operation.SEALED QUENCH FURNACESealed quench furnace as a name defines, provides quenching under protective atmosphere. The furnace comprises main heating chamber, inlet vestibule, oil quench tank and upper lento cool chamber. It is also known as Muffle or intrinsic quench furnace.In this project defines sealed quench furnace is chosen it has furnace has both heating and cooling process combined in one unit. The penetrateing of the furnace is industrial invention.In industry side the furnace is used for moulding of metals such as engine parts, shift, etcMATERIALS RELATED TO PROJECTLABVIEWLabview is a acronym for Laboratory virtual(prenominal) Instrumentation Engineering Workbench. It is a graphical programming language. There is no text-based program code like other programming languages, but thither is a diagrammatic view of how data flows through the program. Labview is loved pecker for scientists and engineers because conventional programming language is built and the task is achieved. Labview is introduced in 1986 and developed by National instruments. It is easily learn programming language. It is chosen because it is accelerated than other programming languages. The development in Labview program is 4 multiplication faster than other languages. The virtual instrument developed using Labview is, in short called a VI.Uses of LabviewFaster programmingHardware integration advanced(a) AnalysisMultiple targets and OSMultiple Programming ApproachesProfessional substance abuser InterfacesMulticore ProgrammingSaves time and moneyIncreased FlexibilityApplications of LabviewAcquiring selective information and processing signalsAutomating test and well-groundedation systemsDesigning Embedded systemsInstrument controlindustrial measurements and controlAcademic Teaching and ResearchPolymer Technology polished and Structural EngineeringDefenceTextilesBio-medical EngineeringMetallurgyhttp//cnx.org/content/m15428/latest/ LabviewIndustrial ApplicationsIt is used in Aircraft industry for making of aircraft engine components such as oil pumps, clutches, pinions, yokes, pins, manometer pistons, aircraft carriages etc.It is used in Bearing Industry bearing ringsIt is used machine building industry drive axis, gear axles, gear wheels, toothed rings, hydraulic and pneumatic elements, bolts etcIt is used in automotive industry for making of gear box components and drive axles (shafts, gears etc.)CHAPTER 3 corpse OVERVIEWBLOCK DIAGRAMlabview1 work up 2.1 Sealed quench furnace with control systemThe block diagram of sealed quench furnace is shown in figure 2.1. It consists of Labview control system, Endo hired gun, Carrier gas, Air supply module, and Air pipe.Figure 2.2 Overview of sealed quench furnaceThe sealed quench furnace has two chambers separated by unflinching lined door which can be opened to allow savory charge to be transferred from heat chamber to cool chamber. In order to determine the systems requirements, the parameter using to control the furnace are Temperature, Pressure, Oxygen level, pay heed switch and rude(a) materials level. The temperature of the furnace is monitored by thermistor. The first process is in heat chamber is the heating of materials and is controlled by atmosphere, LPG, Indo gas, Nitrogen. Nitrogen is used for safety purpose because use of LPG and indo gas. Indo gas and nitrogen forms carbon potential manage the raw materials used in the furnace. The control valves pressure and oxygen is monitored by demodulators. Temperature sensor is used for the actual process held in the furnace.The second process is in the Quench chamber is cooling of materials. In this controlling valves are used for controlling of the furnace. The flow switch is used for level maintenance.In this Labview control system, it has monitor and control of the furnace, with inputs of temperature, oxygen, Endo gas, and pressure. The temperature of the furnace exists the predefined limit it automatically increases the air level and reduces the gas enter in the furnace. The pressure of the furnace is increases the above the set limit today out the air from the furnace. When temperature of the furnace reduces the set limit automatically increases the gas enters into the furnace.CHAPTER 4SYSTEM DESIGNStep1Labview 8.6 version is installed and activating on the system.Step2Figure 4.1 straw man strain of LabviewOpen Blank VI for new project design. In this two windows are opening 1) Block diagram and2) Front plankStep 3Press CTRL+E, CTRL+T for both windows shows p arallel. It gives flexibility and motive can see the both concealment simultaneously. It is shown in figureFigure 4.2 cascade windows of LabviewStep 4In this deigning the monitoring and controlling of furnace, includes the fiver screens as follows screen Main screen, Report screen, Run screen, Setup screen and most us screen.MAIN SCREENThe main screen has About Us, Report, Run, Setup, Exit and login motion-picture shows. The run icon interconnects to the run module. The frame-up icon interconnects to the setup module screen. The Report icon interconnects to the report screen. The about us icon interconnects to the about us screen.Figure 4.3 main screen front instrument graceFigure 4.4 Block diagram of main screenStep 5Setup screenIn set up screen the settings of furnace are listed.Figure 4.5 Setup screen front panelFigure 4.6 setup screen block diagramStep 6Report screenFigure 4.7 report screen front panelFigure 4.8 report screen block diagramStep 7Run screenFigure 4.9 run s creen block diagramStep8About Us screenFigure 4.11 About us screen front panelFigure 4.12 About us screen block diagramCHAPTER 5TESTING AND EVOLUTION riddles AriseThe Labview is the latest programming tool and there are not enough reference books are available.Labview is latest design tool how to use this softwareThe designing of setup screenProblem solutionLabview information is get from internet source and some books are getting from national library.Attend the seminar at national instruments, Singapore for using of Labview.CHAPTER 6Advantages, Disadvantages and Applications1. Advantages of sealed quench furnaceLess distortionProcess repeatability negligible pollutionFully automated,Avoids manual errorsSystematic analyzingWastage minimized and cost deliveranceConsistency in case depth and surface hardness.2. Disadvantages of sealed quench furnaceVery fast quenchCorrosive quench tankFixtures and modificationHigh costHigh safety needLimitation of lading (750 / 1000 kgs)Power cons umption highUse only particular gasesRepeated process not applicableOnly used hot quenching oil (oil cost high).3. Features of sealed quench furnace are shown infraRe-carburizing.Controlled atmosphere annealingBright annealingCarbonitridingNormalizingHardeningCarburizing-hardeningCarburizing4. ApplicationThe sealed quench furnace using applications are shown belowIndustrial ApplicationsGear makingEngine partsStainless less steel materialsmaking of toolsMaking of steelsMaking of machine parts, etcPROJECT MANAGEMENTCHAPTER 7CONCLUSIONThe monitoring and controlling of sealed quench furnace using Labview is designed and tested with valid parameters. The Monitoring and controlling of sealed quench furnace is successfully tested and experiences all the objectives required to function accordingly. The problems arise were encountered, it is manageable and solved with technical guidance.The conclusion from the performance results areGraphical programming is flexible and easy.Program desig n can be changed easily based on the customer requirements. overall the system is efficientRECOMMENDATIONThe prototype was successfully developed to meet its objectives but it could be further improved based on computer hardware design.