Production versatility increased in semi-continuous ... - Seco-Warwick

Production Versatility Increasedin Semi-Continuous ControlledAtmosphere Brazing FurnaceSECO/WARWICK S.A.2 nd International Congress “Aluminium-Brazing”15 th to 17 th May, 2002 in DüsseldorfPIOTR SKARBIŃSKI – ProductManager CAB FurnacesSECO/WARWICK Ltd.ul. Sobieskiego 866-200 ŚwiebodzinPOLANDJEFF BOSWELL – VicePresidentSECO/WARWICK Corp.180 Mercer StreetMeadville,PA 16335 USA

Available CAB furnace systems• OEM ManufacturersSECO/WARWICK S.A.- continuous lines for large runs / mid size productionRADIATION TYPE CAB FURNACECONVECTION PREHEAT / RADIATIONBRAZE TYPE CAB FURNACECONVECTION TYPE CAB FURNACE

Available CAB furnace systems• Aftermarket manufacturers• Small radiator shops• R&D laboratories- wide variety of products in short /mid runs – maintaing OEM qualitySECO/WARWICK S.A.SEMICONTINUOUS ACTIVE ONLY ® FURNACE

Semicontinuous CAB Furnace Active Only ®TYPICAL BRAZING TIMES FOR AOUTOMOTIVE HEAT EXCHANGERS INRADIATION FURNACE:Radiators:CACCondensersHeater cores12 - 16 min15 - 24 min12 - 16 min10 - 14 minSECO/WARWICK S.A.Practical benefit of Active Only ® semicontinuousfurnace:- load of radiators followed by load of CAC, followed by doublelayered condensers followed by load of heater cores, each load ofdifferent massSame high brazing quality for variety load obtainedusing the same parameter settings.

Semicontinuous CAB Furnace Active Only ®SECO/WARWICK S.A.- Indexing type mesh belt.- Interval of indexing based on feed back from control system.- Cycle time : time to reach the pre-set brazing temperature +desired soak time at brazing temperature.- Typical output: 3-5 loads per hour.

Semicontinuous CAB Furnace Active Only ®Control STRATEGY:• Fan Speed Control T/Cs read loadtemperature and control the fanspeed to obtain as fast as possibleheating rate during heating phaseand the best temperature uniformityat brazing phase.SECO/WARWICK S.A.• When fan speed T/Cs read the setvalue, soak time is started to becounted.• Slowing down of fan speed atbrazing temperature (when the cladis molten) prevents mat lookingparts.Results of control strategy :- shortest possible heating time for every load- fixed soak time

Furnace Active Only ®- Phases of process:- loading the tray on conveyorSECO/WARWICK S.A.- drying / thermal degreasing- purging in entrance chamber- brazing- atmosphere cooling- air blast cooling

SECO/WARWICK S.A.

Experiment to the display versality of ActiveOnly ® systemPlate cup evaporatorsPart weight 4 kgDimensions 254 x 279 x 102 (mm)Surface area 0.24 m 2Fixture weight 17.4 kgDatapaq weight 7.5 kgParts per load 15Total weight 85 kgSECO/WARWICK S.A.-Degreaser temperature 265 o C-Furnace temperature 621 o C-Soak temperature 604 o C- Soak time 150 sec.- Cooling water temperature 40 o C-The furnace atmosphere for bothparts was maintained at less than20ppm O 2 and a –40 o C dew point.- Nitrogen consumption wasmeasured at 43 m 3 / h-Flux was applied to the parts at arate of 2g/m 2 using an electrostaticfluxer without washing the parts.Parallel flow condensersPart weight 4.3 kgDimensions 762 x 508 x 34 (mm)Surface area 0.8 m 2Fixture weight 34.9 kgDatapaq weight 7.5 kgParts per load 6Total weight 68 kg

Experiment to the display versality of ActiveOnly ® systemSECO/WARWICK S.A.Brazing time of 1196 secondsBrazing time of 1024 secondsRESULTSBoth types of load successfully brazedin the same parameters with no leaksat temperature uniformity +/- 2 o C

Semicontinuous CAB Furnace Active Only ®SECO/WARWICK S.A.DOUBLE LAYERED CONDENSERS BRAZED IN ACTIVE ONLY ® FURNACE

Semicontinuous CAB Furnace Active Only ®SECO/WARWICK S.A.Core Size2,000 mm x1,300 mm x100 mm ThickConsidered tobe one of thelargest coresbrazed using anon corrosiveflux.

Semicontinuous CAB Furnace Active Only ®Advantages of using convection:- Higher heating rates.SECO/WARWICK S.A.- Higher temperature uniformity, usually better than +/-3 o C.- The same heating time for fins and headers enablesusing for the whole core the same material: clads AA4343 or AA 4045 instead of AA 4045 for fins and AA4049 for header.

Standard sizes - Active Only ®915 x 1830 x 203 mm 1397 x 2286 x 330 mmSECO/WARWICK S.A.

Active Only ®- Main Design features- low thermal mass ceramic fibre insulationSECO/WARWICK S.A.- patented convection muffle design- combustion system based on high velocity burners- Advanced convection fan design.Above features provide fast and uniform heat transfer tothe load enabling to obtain desired brazing profile.

Active Only ®- Main Design featuresSECO/WARWICK S.A.ATMOSPHERE COOLING CHAMBERFAST/CONTROLLED COOLING OPTION - COOLING RATE > 1 o C / SECOND

PC/PLC Furnace Control System ACCUBRAZE ®LINE OVERVIEWSECO/WARWICK S.A.

PC/PLC Furnace Control System ACCUBRAZE ®RECIPESECO/WARWICK S.A.

PC/PLC Furnace Control System ACCUBRAZE ®SERVICESECO/WARWICK S.A.

PC/PLC Furnace Control System ACCUBRAZE ®MAINTENANCE ACTIVITIESSECO/WARWICK S.A.

PC/PLC Furnace Control System ACCUBRAZE ®HISTORICAL TRENDSSECO/WARWICK S.A.

PC/PLC Furnace Control System ACCUBRAZE ®NITROGEN & SAMPLING SYSTEMSECO/WARWICK S.A.

Benefits of SemicontinuosCAB Furnace - Active Only ®New TechnologySECO/WARWICK S.A.Ability to operate on a “ part time “ basis.Minimal heat up time from ambient.Flexibility when running different sized loads one afteranother.Excellent Temperature Uniformity.Fan Speed Thermocouple control system.Ideal for Aluminium Core After Market.

SECO/WARWICK S.A.THANK YOU FORATTENTION