Shenzhen vibration aging machine for stress relief

Shenzhen vibration aging machine, welding stress relief equipment, and aging vibration instrument have received high praise from a large number of users since they were put into the market.

The vibration aging machines currently used on the market are mainly controlled by microcontrollers, with the model being 89C51. It is a microcomputer that integrates a microprocessor, a certain capacity of RAM and ROM, as well as I/O ports, timers, and other circuits on a single chip. The 89C51 integrates a 4 KB FLASH ROM, with a total of 5 interrupt sources. A two digit hexadecimal number can represent 256 storage units. The application of vibration aging machines is reflected in the advantages of simple use, high reliability, and good real-time performance, but there are also disadvantages such as difficulty in transplantation and lack of necessary technical support, especially unlike commercial embedded systems that are widely used and continuously researched and updated. Therefore, our company's technical personnel have decided to develop a more technical and reliable control system, using PLC control.

Essentially, the vibration aging machine using PLC control is actually a set of pre made 51 microcontroller systems.

But PLC also has its own characteristics: PLC widely uses ladder diagrams instead of computer language, which has certain advantages in programming vibration aging machine programs. You can understand ladder diagrams as being similar to calculator languages such as assembly, but with a different scope of use! And the usual practice is for PLC software to convert your ladder diagram into C or assembly language, and then use assembly or C compilation system to compile it into machine code. PLC only runs machine code. The ladder diagram can make it easier for vibration aging machine users to operate.

The reason why vibration aging machines can partially replace thermal aging in practical applications is inseparable from some obvious characteristics of this technology.

1. Low investment and strong applicability. Compared with traditional thermal aging, it does not require a large aging furnace. In modern industry, there are more and more large castings and welded parts. If thermal aging is used to eliminate stress, a large aging furnace needs to be built, which is not only expensive and low in utilization, but also difficult to achieve uniform temperature inside the furnace, resulting in poor stress relief effect. Using vibration aging can * avoid these problems. Therefore, vibration aging is widely used for large welded parts of bridges, ships, chemical equipment that are several meters to tens of meters long, and ultra heavy castings that weigh several tons to tens of tons.

2. Short production cycle and high efficiency. Thermal aging often takes several tens of hours to complete, while vibration aging generally only takes a few tens of minutes to complete. Moreover, vibration aging is not limited by the site and can reduce the round-trip transportation of workpieces before and after aging. If the vibration equipment is installed on the mechanical processing production line, it not only makes the production schedule more compact but also eliminates the stress generated during the processing.

3. Easy to use. The vibration aging equipment is small in size, light in weight, and easy to carry. Currently, the vibration exciter produced in China can vibrate and process workpieces weighing less than 300 tons, but the vibration device itself weighs only a few tens of kilograms. It is precisely because vibration treatment is not limited by the site and the vibration device can be carried to the site that this process is simpler to use and has stronger adaptability compared to thermal aging. It can be arranged between any processes and can be carried out multiple times.

4. Save energy, reduce costs, and avoid pollution such as waste residue, exhaust gas, and radiation. Performing aging treatment at the resonance frequency of the workpiece results in minimal energy consumption. Practice has proven that mechanical vibrators with a power of 0.25 to 1 horsepower can vibrate workpieces weighing less than 150 tons. Its energy consumption is only 3-5% of thermal aging, and its cost is only 8-10% of thermal aging. In addition, during thermal aging, coal, oil, and other fuels are inevitably used to discharge a large amount of waste residue, exhaust gas, etc., which cannot meet the increasingly high environmental requirements. Therefore, vibration aging has gradually become a good choice for stress relief.

5. The mechanical performance has significantly improved. After vibration aging treatment, the residual stress of the workpiece can be eliminated by about 20-80%, and the elimination of high tensile stress areas is greater than that of low stress areas. It can improve the strength and fatigue life of use, and fundamentally prevent defects such as warping deformation, oxidation, decarburization, and hardness reduction that occur in metals during thermal aging. It can also improve the deformation resistance of components, stabilize the accuracy of components, and enhance mechanical quality.

Practice has proven that vibration aging machines are suitable for stress relief of castings, forgings, welded parts, and machined parts made of carbon structural steel, low-alloy steel, stainless steel, cast iron, non-ferrous metals (copper, aluminum, zinc, and their alloys), and other materials.

The current vibration aging process equipment is to place a motor system (exciter) with an eccentric weight on the workpiece with a fixture and support the workpiece with elastic objects such as rubber pads. Start the motor through the host control and adjust its speed to make the workpiece in resonance state. Generally, the residual stress of the workpiece can be adjusted by vibration treatment for 15-30 minutes.

Instructions for using fully automatic vibration aging system

1. Overview

Vibration aging is the use of resonance principle to eliminate and homogenize residual stresses in metal castings, forgings, welded structural components, non-ferrous metals and other parts, in order to prevent dimensional deformation and cracking of the parts. Compared with traditional heat aging methods, it can save energy by 95%, reduce production costs by 80-90%, shorten production cycles by about 90%, and does not produce aging oxidation skin; No environmental pollution, not limited by part size, site, etc., and the time effect is intuitive and superior to thermal aging.

The vibration aging process is shown in the following figure: it is to place a motor system (exciter) with an eccentric weight on the workpiece with a fixture and support the workpiece with elastic objects such as rubber pads. The motor is started by the host and its speed is adjusted to make the workpiece in resonance state. Generally, the residual stress of the workpiece can be adjusted by vibration treatment for 10-40 minutes.