What is the bending principle of flat bend tempering furnace?

The bending principle of a flat bending tempering furnace involves heating and shaping glass sheets into curved or bent forms. This process, widely used in manufacturing applications such as automotive and architectural glass, uses controlled heating, bending, and tempering to achieve the desired shape and mechanical properties.

Bending principle of flat bending tempering furnace

flat bending tempering furnace

1. Heating Phase

The flat glass sheet is placed on rollers and enters the furnace, where it is gradually heated to the softening point (typically around 600-700°C, depending on the glass type).

The heating is carefully controlled to ensure uniform temperature distribution across the glass. Uneven heating can cause distortions or weak points.

2. Bending Process

Once the glass reaches the target temperature and becomes pliable, it is moved to a bending station where the actual shaping occurs. There are two main bending methods in flat tempering furnaces:

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What are the types of glass tempering furnaces?

Tempering furnaces are used in heat treatment processes to modify the properties of materials, typically metals, after they have been quenched (hardened) to adjust their hardness, ductility, and strength. There are several types of tempering furnaces, each designed for specific tempering needs, production volumes, and heating capabilities.

Tempering Furnace Type

Tempering furnaces

1. Batch Tempering Furnace

Description: A batch tempering furnace is designed to heat a batch of parts all at once. The workpieces are placed in a furnace chamber, heated to the desired temperature, held for a specific time, and then cooled.

Applications: Used for tempering a variety of small to medium-sized batches of parts, typically in industries like automotive, aerospace, and tool manufacturing.

Key Features:

Simple and versatile

Suitable for low to medium production volumes

Can have electric or gas heating

Limitations: Less efficient for high-volume production compared to continuous furnaces.

2. Continuous Tempering Furnace

Description: A continuous tempering furnace allows parts to move through the heating and cooling sections of the furnace on a conveyor or roller system. The furnace is designed for continuous processing.

Applications: Used for high-volume production, particularly in industries that require the mass tempering of parts, such as automotive or large-scale manufacturing.

Key Features:

High throughput for large-scale production

Can provide uniform temperature distribution

Often equipped with automated controls and conveyors

Limitations: Higher initial investment and maintenance costs compared to batch furnaces.

3. Pit Tempering Furnace (or Forge Furnace)

Description: This type of furnace is typically used for larger, heavier workpieces. It’s a vertical furnace where parts are placed in a pit and heated, often used for special tempering processes.

Applications: Ideal for large or heavy parts such as those in the forging, construction equipment, or power generation industries.

Key Features:

Heavy-duty, suited for larger parts

Can handle high temperatures

Often used for specialized, low-volume processes

Limitations: Less common for small- to medium-sized production runs.

Tempering furnaces

4. Electric Resistance Tempering Furnace

Description: In these furnaces, electric heating elements (usually made of resistance wire or coils) heat the chamber. The temperature is controlled by adjusting the electrical current passing through the heating elements.

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Manufacturing process of slewing bearing and detailed steps

Slewing bearings are also called turntable bearings. The main structure includes: inner ring, outer ring, rolling element and rolling element guided cage. It is an important transmission component in mechanical equipment. It is widely used in engineering machinery, light industrial machinery, metallurgical machinery, medical machinery, ship equipment and other industries. Today, the slewing bearing manufacturer will take you to understand the manufacturing process and detailed steps of the slewing bearing.

Slewing bearing manufacturing process

Slewing bearing

1. Cutting of slewing bearing steel raw materials

The commonly used raw materials for slewing bearings are integrally hardened carbon chromium bearing steel, and the slewing bearing rings are made of surface hardened steel, generally made of 50Mn steel. The cylindrical raw material billets transported back from the steel plant are cut according to the size required for processing the bearings. Generally, carbide saw blades should be used for cutting bearing steel, which has a series of excellent properties such as high hardness, wear resistance, good strength and toughness, heat resistance, and corrosion resistance.

2. Forging of slewing bearing billets

In the heating furnace, the billets are heated and forged into a round cake shape. The forging link is an important link to ensure the reliability and life of the bearing. After forging, the raw materials form the bearing ring blank. At the same time, the organizational structure of the raw materials becomes more dense and streamlined, which can improve the reliability and service life of the bearing. In addition, the quality of the forging process will directly affect the utilization rate of the raw materials, thereby affecting the production cost.

3. Forging ring of slewing bearing

The steel blank is forged into a ring-shaped steel ring by using a ring rolling machine. Forging can improve the internal organization of steel and improve the strength, plasticity, impact toughness and other mechanical properties of steel.

4. Rough turning

The steel ring after ringing is loaded into the machine tool for rough turning of machining, and various grooves and raceways are turned out. The steel ring is fixed on the gear milling machine and the teeth are cut out. The main purpose is to make the ring after the ring is the same as the shape of the final product, creating conditions for the later grinding machine processing.

5. Quenching (heat treatment) of slewing bearing

After machining, the strength and hardness of the steel are improved through quenching operation, and the wear resistance, fatigue strength and toughness of the metal are improved. The heat treatment process is to treat the bearing rings after forging and turning at high temperature. It directly affects the uniformity of carburization in the bearing rings, can improve the wear resistance and hardness of the bearings, and is also an important link that affects the reliability and life of the bearings.

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How to maintain the double-row ball slewing bearings

Double-row ball slewing bearings are based on the design of two parallel raceways, in which force transmission and rotary motion are achieved by the upper and lower rows of steel balls or rollers of different diameters rolling in the raceways. This design enables the slewing bearing to withstand large axial forces and tilting moments while maintaining structural stability and rotational flexibility.Maintaining double-row ball slewing bearings is crucial to ensure their optimal performance, longevity, and reliability.

Double-row ball slewing bearings maintenance

Double-row ball slewing bearings

1. Routine Inspection

Frequency: Conduct visual and operational inspections at least monthly or as recommended.

What to Check:

Physical Damage: Look for cracks, wear, or corrosion on the raceway and balls.

Unusual Sounds: Listen for abnormal noise during operation.

Clearance: Measure axial and radial clearances; deviations may indicate wear.

Smooth Rotation: Check for resistance or stiffness in movement.

2. Proper Lubrication

Type of Grease: Use a high-quality grease as recommended by the manufacturer (e.g., lithium-based grease).

Frequency:

Re-grease every 50-100 operating hours or based on conditions like load and environment.

Increase greasing intervals in dusty, wet, or high-temperature environments.

Procedure:

Rotate the bearing slowly while applying grease to ensure uniform distribution.

Remove old grease and contaminants before applying new grease to prevent contamination.

3. Bolt Tightening

Inspection Interval: Check bolts every 100 operating hours or after heavy use.

Tightening Torque: Use a torque wrench to tighten bolts to the specified values from the manufacturer.

Replacement: Replace worn, loose, or corroded bolts immediately to prevent failure.

Double-row ball slewing bearings

4. Sealing System Maintenance

Inspection: Regularly check seals for wear, damage, or displacement.

Cleaning: Clean the area around the seals to remove debris and contaminants.

Replacement: Replace damaged seals to maintain proper sealing and prevent foreign particles from entering.

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How to install four-point contact ball bearings

Four-point contact ball bearings are designed to handle axial loads in both directions and moderate radial loads. They are commonly used in applications requiring combined loading (axial and radial) and where space is limited.

Four-point contact ball bearing installation guide

Four-point contact ball bearings

1. Preparation

Ensure the bearing, housing, and shaft are clean, free from any debris, dirt, or burrs that could affect performance.

Check the parts for any damage or imperfections.

Apply a thin layer of high-quality grease or lubricant to the seating surfaces to ease installation and prevent corrosion.

2. Align the Bearing

Align the bearing with the shaft or housing properly before applying force. Misalignment during installation can lead to excessive load, resulting in premature wear.

Note the direction of loading: four-point contact bearings have a split inner or outer ring, and the load should be directed through the split points.

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How to select four-point contact ball bearings

Four-point contact ball bearings are radial single row angular contact ball bearings designed to support axial loads in both directions. They can support a certain degree of radial loads and take up significantly less axial space than double row bearings. The inner ring is a split inner ring, which allows a higher number of balls to be loaded and increases the load carrying capacity. Selecting a four-point contact ball bearing involves considering several key factors to ensure it suits the specific application.

Four-point contact ball bearing selection

four-point contact ball bearings

1. Load Type and Magnitude

Axial Load: Four-point contact ball bearings can handle both radial and axial loads. Ensure that the bearing’s axial load capacity meets the application’s requirements.

Radial Load: Determine the radial load the bearing will be subjected to. Four-point contact ball bearings typically have a lower radial load capacity compared to other ball bearings, so this needs to be considered.

Combined Loads: Four-point contact bearings are particularly useful in applications where both radial and axial loads are present. Make sure to calculate and consider the resulting combined load.

2. Bearing Size and Internal Geometry

Bearing Diameter: The size of the bearing should match the shaft diameter or housing in which it will be installed.

Contact Angle: Four-point contact bearings have a contact angle of about 35° that allows them to support both axial and radial loads. Check if this angle aligns with your application’s needs.

Clearance or Preload: This defines the amount of internal clearance between the rolling elements and raceways, which influences the bearing’s performance under load.

3. Speed Requirements

Rotational Speed: Four-point contact bearings are generally suitable for moderate to high-speed operations, but you should verify the maximum speed the bearing can handle by checking the manufacturer’s catalog.

Lubrication: High-speed applications may require special lubrication (oil or grease). Make sure to select a bearing that is compatible with the lubrication type you plan to use.

4. Environmental Conditions

Temperature: Consider the operating temperature range. Some four-point contact ball bearings are available with seals or shields for dust, moisture, and temperature resistance.

Corrosion Resistance: If the bearing will be exposed to corrosive environments (e.g., chemicals or water), choose a bearing with appropriate material coatings, such as stainless steel or ceramic bearings.

four-point contact ball bearings

5. Precision Requirements

Precision Class: Bearings come in different accuracy classes (e.g., P0, P6, P5). For high-precision machinery, select a bearing with a higher accuracy grade.

Radial Runout and Axial Runout: For high-precision applications, the bearing’s radial and axial runout tolerances should be evaluated.

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What are the maintenance procedures and requirements for vibrating screen exciters?

In the field of industrial equipment maintenance, the vibrating screen exciter is one of the key equipment. During its maintenance process, a series of steps and standards must be followed to ensure its reliability and durability. The maintenance process of the vibrating screen exciter includes a series of strict operations, from taking photos and archiving the original machine state at the factory to the comprehensive process of painting and shipping. Each step significantly affects the results of the maintenance quality. In order to ensure the quality of maintenance, the various requirements in the maintenance of the vibrating screen exciter are also particularly critical. From bearings to housings, to gears and other parts, relevant standards and specifications must be strictly followed to ensure that the expected working performance can be achieved after maintenance.

Maintenance process of vibrating screen exciter

vibrating screen exciter

Take photos of the original machine state upon entering the factory and archive them → Shot peening → Primer spraying → Disassemble the vibrating screen exciter → Take photos of parts and archive them → Clean parts → Inspect, test and archive them → Issue test report → Salesperson and user confirm the damage and form a damage confirmation form → Develop maintenance plan → Receive parts → Inspect, record and archive → Ultrasonic cleaning → Assembly → Test and record into files → Paint → Ship

Maintenance requirements of vibrating screen exciter

vibrating screen exciter

1) Bearings

Must be replaced during maintenance, and high-quality SKF vibrating screen bearings must be selected to ensure that they can withstand high-intensity vibration working environment and maintain long-term stable operation. Careful installation and adjustment work is also essential to ensure the correct installation position and normal working state of the bearings.

2) Seals

Replacement of seals is an important guarantee to ensure the normal operation of the exciter. When replacing, high-quality seals that match the originals must be selected to ensure that they can effectively prevent the leakage of lubricating oil or other substances, thereby protecting internal parts from damage.

3) Box body

The box body with cracks, deformation, thread damage and wear must be replaced; when the box body hole and the bearing outer ring installation position are worn and the bearing does not meet the assembly requirements, it must be replaced. The new box body should be made of high-strength ductile iron QT400-12 material, without defects such as slag inclusions, pores, cracks, etc. and ultrasonic flaw detection to ensure its durability and stability. During the box body processing, the precision processing process of the CNC machining center should be strictly implemented to ensure the accuracy and stability of the box body.

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What are the maintenance procedures and requirements for vibrating screen exciters?

In industries such as mining and coal preparation, materials need to be screened and classified before they can be used. Vibrating screens use mechanized vibration to classify materials according to different sizes. They have a large processing capacity and high screening efficiency, which is many times more efficient than traditional manual sorting. They can be said to be a “good helper” for screening work. However, if the screen is used improperly, it will cause mechanical failures and short service life. In order to avoid these problems, you need to learn more about the operating steps and precautions of the vibrating screen.

Vibrating screen operation steps

Vibrating screen

1. Inspection before starting

(1) Check whether the starting equipment is in good condition, whether the motor is grounded properly, and adjust the tightness of the V-belt.

(2) Clear the debris on the screen to avoid heavy load starting.

(3) Check and tighten the bolts of each part.

(4) Check and add enough lubricating oil in the vibrator.

(5) Check whether the inlet and outlet chutes are unobstructed, check whether the crossbeams are welded, and check whether the safety protection devices are safe and reliable.

(6) After completing the above preparations, you can send a signal to notify the start-up.

2. Start the machine

Turn the control switch handle to the forward position of the motor, press the start button, close the switch, and start the motor. Observe the operation status. There is no abnormal sound or vibration. It can only run normally after it runs smoothly. It can only be fed after it runs normally. Before starting the equipment, it must be ensured that the discharge port transportation equipment has started and run normally. After confirming that the operation of the vibrating screen is completely normal, send a signal to notify the discharge.

3. Equipment operation

The feeding must be uniform, and it cannot be overloaded or have excessive impact. Pay attention to the temperature and abnormal sound of the motor at any time. Always pay attention to the discharge situation. If there is any blockage, it must be cleared in time. Inspect the nozzle of each vibrating screen for blockage or detachment, and observe the temperature and sound of the motor and the sound of the exciter frequently. Any repair or adjustment of the vibrating screen during operation must be carried out after the power supply of the machine is cut off and the sign prohibiting closing is hung.

4. Equipment shutdown

Stop feeding before shutting down, and shut down after the material on the screen surface is drained. Pull down the knife switch and close the pressure water gate. Turn the control switch handle to the stop position. Ring the stop bell for the unloading transportation system. Clean the vibrating screen and the work site. In special circumstances, the machine can be shut down immediately.

Precautions for vibrating screen operation

Vibrating screen

1. Pay attention to the bearings of the transmission part. Check the bearing temperature in the middle and end of each shift during the operation of the screen machine, check the amplitude of the screen machine under normal load and peak load of the screen machine, and observe the operation of the screen machine at any time. The normal operating temperature rise is 35℃, the ambient temperature is 25℃, the bearing temperature rise is higher than 70℃, and the ambient temperature is 25℃, the parking operation is executed.

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Vibration Motor Installation Method Guide

Installing a vibration motor requires careful attention to alignment, support, and mounting to ensure reliable operation and minimize wear or vibration transmission to unwanted areas.

General guide on vibration motor installation:

vibration motor

1. Prepare the Installation Surface

Ensure the surface where the motor will be mounted is clean, level, and rigid. Any unevenness or instability in the mounting surface can cause excessive vibration and reduce motor life.

Reinforce the mounting area if necessary, as a strong foundation will help absorb vibration and prevent damage to surrounding equipment.

2. Mounting the Motor

Use bolts that are strong enough for the motor’s size and vibration force. High-grade bolts are recommended to secure the motor tightly.

Place vibration-damping pads or rubber mounts between the motor and the mounting surface to help absorb vibrations and prevent them from transferring to other parts of the machine.

Tighten the bolts evenly to ensure that the motor is securely and uniformly attached. This helps to distribute the load and minimize imbalances.

3. Alignment and Positioning

Align the motor properly with the vibrating equipment to avoid misalignment, which can cause excessive wear and increase vibrations.

Position the motor according to the manufacturer’s recommendations, as improper placement can lead to uneven or excessive vibrations. For example, some setups may require placing the motor at a specific angle or orientation.

Make sure there is sufficient clearance around the motor for maintenance and to allow airflow for cooling.

vibration motor

4. Electrical Connections

Follow the manufacturer’s wiring instructions carefully to connect the motor to the power supply. Make sure to use appropriately rated cables and connectors.

Use cable clamps to secure the wiring to prevent it from being affected by vibrations, which can lead to wear or electrical issues over time.

Ground the motor properly to ensure safety and prevent electrical noise from affecting nearby equipment.

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How to install the vibrating screen bearing

Installing bearings in a vibrating screen is a critical task that requires precision to ensure that the machine operates effectively, minimizes downtime, and maximizes bearing life. Vibrating screens operate under harsh conditions, with heavy loads and high vibration, so proper bearing installation is essential to prevent premature failure.

Vibrating screen bearing installation

vibrating screen

1. Prepare for Installation

Gather Tools and Materials: Make sure you have the necessary tools and equipment, including the correct bearings, tools for mounting (e.g., bearing pullers, wrenches, hammers), grease or lubricant, cleaning materials, and any special tools for your screen design.

Ensure Proper Conditions: Perform the installation in a clean, dry environment to avoid contamination of the bearings. If necessary, use a workbench with sufficient space to handle the components.

2. Inspect the Bearings

Check for Damage: Before installation, inspect the bearings for any signs of damage (such as cracks or dents) or contamination. Ensure the bearings are the correct size and type for your vibrating screen.

Clean Bearings: If the bearings are new, ensure they are free of dirt or debris. Wipe the bearings with a clean cloth if needed. If you’re reusing old bearings, thoroughly clean them before installation.

3. Prepare the Housing and Shaft

Inspect the Shaft and Housing: Ensure that the shaft and housing where the bearings will be installed are in good condition. Look for any wear, damage, or signs of corrosion that could affect bearing performance.

Clean the Shaft and Housing: Clean both the shaft and bearing housing with a lint-free cloth to remove any dirt, dust, or oil. If necessary, lightly polish the surfaces with a fine abrasive cloth.

Check for Tolerances: Verify that the shaft and housing have the correct dimensions to match the bearing’s internal and external diameters. The fit should not be too tight or too loose.

4. Install the Bearings

Apply Grease or Lubrication: If the bearings are grease-lubricated, apply a thin layer of grease to the inner race and the shaft. Use only the recommended type and amount of lubricant. If the bearing is sealed, it may not require lubrication before installation.

Use Bearing Installation Tools: Use proper tools to install the bearings. It is crucial not to damage the bearing by applying force directly to the rolling elements (balls or rollers). Use bearing fitters or sleeves to apply pressure to the outer race of the bearing only.

Install the Bearing on the Shaft: Gently slide the bearing onto the shaft, ensuring it moves smoothly without excessive force. Do not hammer or force the bearing onto the shaft. If the bearing is tight, use a press to push it into place evenly.

Install the Bearing in the Housing: Similarly, install the other bearing into the bearing housing. Ensure that the bearing is properly seated and aligned with the housing.

vibrating screen

5. Align the Bearings

Check Alignment: Proper alignment of the bearings is crucial to prevent premature wear or failure. Use alignment tools or a straight edge to check that both the shaft and housing are properly aligned.

Ensure Proper Radial and Axial Clearance: Depending on the bearing type, ensure that the radial and axial clearance meet the specifications for the vibrating screen application.

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