Vacuum welding furnace core components analysis and maintenance points

In the modern high-end manufacturing industry, vacuum welding furnace by virtue of its unique advantages in the high vacuum environment to achieve high-quality welding, become an indispensable key equipment in aerospace, electronic information, new energy and other fields. Vacuum welding furnace can accurately complete the task of precision welding, inseparable from its core components of the coordinated operation. xvacuum technology (jiangsu) co., ltd. plows into the field of vacuum welding equipment for many years, the vacuum welding furnace core components of the research and development, manufacturing and maintenance of a deep accumulation of technology and a wealth of experience. In-depth understanding of the core components of the working principle, performance characteristics and maintenance points, to help users better use and maintenance of equipment, to ensure its stable operation, to extend the service life, improve production efficiency and welding quality.

First, the core components of the vacuum system analysis and maintenance

(A) vacuum pump

Vacuum pump is the core of the vacuum welding furnace vacuum system, its main role is to pump the furnace gas to achieve the required vacuum welding. Common types of vacuum pumps are mechanical pumps, Roots pumps, diffusion pumps and molecular pumps. Mechanical pump is the basic pumping equipment, through the reciprocating motion of the piston or rotary vane, the gas will be inhaled and compressed and discharged, commonly used in the pre-evacuation stage, can be reduced to a lower level of the system pressure; Roots pumps are often used in conjunction with mechanical pumps to provide a higher pumping rate within the range of the vacuum to accelerate the pumping process; diffusion pumps and molecular pumps are suitable for high vacuum and ultra-high vacuum environments, diffusion pumps using high-speed vapor Diffusion pumps use high-speed vapor flow to carry gas molecules out, and molecular pumps collide with gas molecules through high-speed rotors to realize pumping. xvacuum technology (jiangsu) co., ltd. selects and configures vacuum pumps according to the needs of different welding processes and vacuum requirements, and scientifically and reasonably combines a variety of vacuum pumps. For example, in the vacuum welding furnace for welding high-temperature alloy parts for the aerospace field, the combination of mechanical pumps and molecular pumps is used, which can quickly complete the pre-evacuation and also achieve the very low pressure required for high-vacuum welding. In terms of maintenance, regular replacement of vacuum pump oil is key. With the increase of use time, the vacuum pump oil will be oxidized, contaminated and degraded performance, you need to replace the oil in accordance with the cycle and method specified in the equipment manual, while cleaning the pump cavity to ensure that the pump is clean; but also to check the pump rotor, rotary vane, and other moving parts of the wear and tear, if any abnormalities in a timely manner to repair or replace the parts, to ensure that the vacuum pump pumping performance is stable.

(ii) Vacuum valve

Vacuum valves are used to control the flow of gas in the vacuum system, flow and on and off, to maintain the vacuum of the furnace and safeguard the safety of the welding process plays an important role. Common vacuum valves include globe valves, angle valves, butterfly valves and plug valves. Globe valves have good sealing, commonly used in parts requiring strict sealing, such as connecting the vacuum pump and the furnace body on the pipeline; angle valves are compact, easy to operate, suitable for space-limited installation environments; butterfly valves have a large flow capacity, suitable for large-diameter pipelines to open and close quickly; plate valves are commonly used in the need for complete isolation of the gas occasions. Stainless steel and other corrosion-resistant materials manufacturing, with high-precision processing technology, to ensure the sealing performance and durability of the valve. In maintenance, we should regularly check whether the sealing ring of the valve is aging and broken, and replace the damaged ring in time to ensure the sealing effect; check whether the opening and closing operation of the valve is flexible, and lubricate and maintain the valve stem and other moving parts to prevent the valve from working properly due to rust or jamming; at the same time, observe the leakage of the valve in the closed state, and if the leakage is found, we need to find out the cause and repair it in time to avoid affecting the Vacuum welding furnace vacuum.

(III) Vacuum piping

Vacuum pipeline is the channel of gas transmission, and its material, diameter and connection directly affect the pumping efficiency and sealing of the vacuum system. Commonly used vacuum pipe materials are stainless steel, glass and plastic, etc., of which stainless steel pipe is most widely used in vacuum welding furnace due to its advantages of high strength, corrosion resistance and good sealing. The size of the pipe diameter should be reasonably selected according to the pumping rate of the vacuum pump and the gas flow rate of the system, the pipe diameter is too small to increase the resistance of gas flow and reduce the pumping efficiency; the pipe diameter is too large to increase the cost and occupy space. Pipe connection methods mainly include welding, flange connection and quick release connection, etc. Welding connection has good sealing, but it is inconvenient for maintenance; flange connection is convenient for disassembly and maintenance, but it requires high requirements for sealing gaskets; quick release connection is easy to operate and suitable for occasions requiring frequent disassembly and installation. xvacuum technology (jiangsu) Co., Ltd. adopts professional fluid dynamics calculation method in the process of designing and installing the vacuum pipes. Optimize the pipeline layout, reduce elbows and unnecessary lengths, and reduce gas flow resistance; strictly control the quality of pipeline welding or connection to ensure reliable sealing. In daily maintenance, we should regularly check whether there are corrosion and cracks on the surface of the pipeline, especially the welding parts and flange connections; clean up the impurities and dust inside the pipeline to prevent them from entering the vacuum pump or the furnace body to affect the operation of the equipment; for the pipeline that has been in use for a long period of time, we can carry out a pressure test to check whether the sealing is good, so as to find and deal with potential problems in time.

Second, the core components of the heating system analysis and maintenance

(A) heating element

Heating element is a vacuum welding furnace to achieve the key components of the welding temperature, its performance directly affects the welding quality and efficiency. Common heating elements are resistance wire, silicon molybdenum rod, graphite heating body. Resistance wire heating element structure is simple, low cost, suitable for low-temperature welding environment; silicon molybdenum rods with high temperature resistance, good oxidation resistance, etc., can work stably in high-temperature environments; graphite heater is commonly used in high vacuum, high-temperature welding occasions, with high heating efficiency, temperature uniformity and good advantages. xvacuum technology (jiangsu) limited company according to the different welding materials and process requirements. XVACUUM Technology (Jiangsu) Co., Ltd. selects suitable heating elements and optimizes their layout according to different welding materials and process requirements. For example, in the vacuum welding furnace for welding electronic chips and other precision parts, high-precision resistance wire heating elements are used, and the uniform distribution of temperature inside the furnace is realized through a reasonable arrangement. In terms of maintenance, regularly check the appearance of the heating element to see if there is fracture, deformation, oxidation, etc. If the heating element is found to be damaged, it is necessary to replace the same type of component in a timely manner, and to ensure that the new component is installed in an accurate position, firmly connected; but also to check whether the heating element terminals are loose, oxidized, to ensure that the electrical connection is good, to avoid local overheating or damage to the heating element caused by poor contact.

(B) temperature control system

Temperature control system consists of temperature sensors, temperature control instrumentation and control circuits, its role is to accurately monitor and control the temperature of the furnace to ensure that the welding process in the set temperature range. The temperature sensor usually adopts thermocouple or RTD, which converts the furnace temperature signal into electric signal; the temperature control meter receives the signal from the temperature sensor and compares it with the set temperature, and adjusts the power of the heating element through the control circuit according to the deviation value to realize the closed-loop control of the temperature. xvacuum technology (jiangsu) co., ltd.'s vacuum welding furnace is equipped with advanced intelligent temperature control system, which adopts high-precision temperature sensor and high-performance temperature control meter, combined with advanced control algorithms, can realize precise control of temperature with a very small temperature fluctuation range. In maintenance, regular calibration of the temperature sensor to ensure its measurement accuracy, can use the standard temperature source for comparison test, if the measurement error exceeds the allowable range, need to adjust or replace the sensor in time; check the display of the temperature control instrument table and the operating function is normal, clean up the surface of the instrument and the internal dust, to prevent the accumulation of dust affecting the heat dissipation and normal operation; check the wiring connection of the control circuit, check whether there is loose aging, and the temperature fluctuation range is very small. Check whether there is loose, aging, damage, etc., to ensure stable and reliable operation of the temperature control system.

Third, the core components of the control system analysis and maintenance

(A) programmable logic controller (PLC)

PLC is the core brain of the vacuum welding furnace control system, it is through the pre-written program, the vacuum system, heating system, cooling system and other components of the logic control and coordinated operation. PLC can be a real-time acquisition of a variety of sensor signals, such as vacuum, temperature, pressure, etc., and according to the pre-set program to analyze the processing, the output control signals to control the corresponding actuators, such as the start and stop of the vacuum pump, XVACUUM Technology (Jiangsu) Co., Ltd. adopts high-performance PLC in the control system of the vacuum welding furnace and develops a powerful, stable and reliable control program by combining rich programming experience. In terms of maintenance, it is necessary to ensure that the working environment of PLC is clean and dry, to avoid dust, moisture and corrosive gases causing damage to it; regularly check the working status of PLC's power supply module, input and output modules and other components, to see whether the indicator light is normal or not, and replace the faulty module in time if there is any abnormality; back up PLC's program, to prevent the equipment from normal operation due to loss or damage of the program, and at the same time, the program can be optimized and upgraded according to the actual needs of the program. At the same time, the program can be optimized and upgraded according to the actual demand.

(ii) human-machine interface (HMI)

Human-machine interface is a window for the operator to interact with the vacuum welding furnace, which is usually composed of a touch screen or a monitor, etc. The operator can set up the welding furnace through the HMI. The operator can set the welding process parameters through the HMI, such as vacuum, temperature, heating time, cooling speed, etc.; real-time view of the operating status of the equipment, such as the current vacuum, temperature curve, the work of the components, etc.; also can carry out troubleshooting and alarm query, timely understanding of the equipment's abnormal information and to take appropriate measures. xvacuum technology (jiangsu) limited vacuum welding furnace The HMI design is simple and intuitive, easy to operate, and has a good human-computer interaction experience. During maintenance, keep the HMI screen clean to avoid scratching or damaging the touch screen; check whether the communication connection between the HMI and the PLC and other control components is normal, and if there is a communication failure, promptly troubleshoot the wiring and interface problems; regularly update the software version of the HMI to obtain better functionality and stability, and at the same time, pay attention to backing up the important setup parameters and data.

IV. Analysis and Maintenance of Other Auxiliary Components

(I) Cooling system

The cooling system is used to cool the key components of the vacuum welding furnace, such as vacuum pump, heating elements, vacuum valves, etc., to prevent damage to the components due to overheating or performance degradation. The cooling system usually consists of cooling pumps, cooling water pipelines, radiators, etc., through the circulation of cooling water to take away the heat generated by the components.XVACUUM Technology (Jiangsu) Co., Ltd.'s vacuum welding furnace cooling system adopts a highly efficient cooling design, to ensure that the components are fully cooled. In terms of maintenance, regularly check the operation status of the cooling water pump to see whether the flow rate and pressure of the pump are normal, and if there is any abnormality, repair or replace the pump in time; clean up the scale and impurities in the cooling water pipeline to prevent the pipeline from being blocked and affecting the cooling effect, and special scale cleaner can be used to clean it; check whether the radiator's fins are blocked, and make sure that the heat dissipation is good; at the same time, pay attention to the quality of the cooling water, and replace the cooling water regularly to prevent the cooling effect due to water quality problems. At the same time, pay attention to the water quality of the cooling water, regular replacement of cooling water to prevent corrosion of cooling system components due to water quality problems.

(ii) Sealing parts

Sealing parts including the furnace door sealing tape, pipe sealing gaskets, etc., their role is to ensure the sealing of the vacuum welding furnace, to prevent the outside air from entering the furnace to affect the vacuum. The sealing strips and gaskets are usually made of rubber, fluoroelastomer, metal and other materials with good elasticity and sealing performance.XVACUUM Technology (Jiangsu) Co., Ltd. selects high-quality sealing materials and adopts advanced sealing structural design to ensure that the vacuum welding furnace has excellent sealing performance. In maintenance, regularly check the aging and breakage of sealing rubber strips and gaskets, and replace the failed sealing parts in time; clean the impurities and dust on the sealing surface to ensure that the sealing surface is flat and clean; when installing the sealing parts, pay attention to the correct installation method and strength, to avoid improper installation leading to poor sealing.

V. Professional maintenance service of XVACUUM Technology (Jiangsu) Co.

XVACUUM Technology (Jiangsu) Co., Ltd. not only provides users with high-performance vacuum welding furnace products, but also committed to providing users with a full range of professional maintenance services. The company has a skilled and experienced after-sales service team, which can provide users with regular inspection, fault repair, parts replacement, technical training and other services. In the process of equipment use, if the user encounters any problems, you can contact the company's after-sales service personnel at any time, the company will respond quickly, through telephone guidance, remote assistance or door-to-door service, etc., to solve the user's problems in a timely manner, to ensure that the equipment runs normally. At the same time, the company also provides users with maintenance training courses to help users' operators and maintenance personnel to master the maintenance points and methods of the core components of the equipment, and improve the user's ability to maintain the equipment independently.

Sixth, the conclusion

The core components of the vacuum welding furnace is the key to achieve efficient and accurate welding, each component plays an indispensable role in the operation of the equipment. Understanding the working principle, performance characteristics and maintenance of these core components is essential to ensure the stable operation of the vacuum welding furnace, improve the welding quality and extend the service life of the equipment. xvacuum technology (jiangsu) co., ltd. with professional technology and rich experience in the field of vacuum welding furnace, not only provides users with high quality equipment products, but also through the perfect maintenance service system, to help users Better use and maintenance of equipment. In the future industrial production, with the continuous improvement of welding quality and efficiency requirements, users should pay more attention to the maintenance of the core components of the vacuum welding furnace, and work closely with professional manufacturers to jointly promote the development and application of vacuum welding technology.