Common faults of rapid temperature rise and fall annealing furnace

The common faults of the rapid temperature rise and fall annealing furnace (RTP) can be classified into five categories: electrical system, heating element, temperature control, mechanical structure, and vacuum system (if applicable). The following are specific fault types and analysis:

1. Electrical system malfunction
power failure
Voltage instability: Unstable power supply voltage may cause equipment to fail to start or operate normally, and the power supply circuit and voltage regulation equipment need to be checked.
Power interruption: Power line failure or damage to power equipment may cause power outages, and the power line and power equipment status need to be checked.
Control component malfunction
Relay malfunction: Worn, adhered, or damaged relay contacts may cause poor control signal transmission and require replacement of the relay.
Contactor malfunction: Worn contactor contacts or damaged coils may cause the motor to fail to start or stop, and the contactor needs to be replaced.
PLC failure: PLC hardware failure or software error may cause the control system to malfunction, and the PLC hardware status and software program need to be checked.
Sensor malfunction
Temperature sensor malfunction: Failure or damage to the temperature sensor may result in temperature control failure, and it is necessary to calibrate the temperature sensor regularly and check its installation status.
Pressure sensor malfunction (if applicable): Failure or damage to the pressure sensor may result in pressure control failure, and the status of the pressure sensor needs to be checked.

2. Heating element malfunction
Heating element fracture
Reason: Heating elements are prone to thermal fatigue fracture during long-term operation in high temperature environments; Mechanical stress, overload operation, and other factors may also cause heating elements to break.
Performance: The heating element suddenly breaks during use, the temperature inside the furnace drops sharply, and the equipment stops working.
Heating element oxidation
Reason: Under high temperature conditions, the surface of the heating element reacts chemically with oxygen in the air to form oxides, resulting in a decrease in material properties.
Performance: Black oxide appears on the surface of the heating element, reducing heating efficiency and increasing energy consumption.
Heating element short circuit
Reason: Short circuit caused by damage to the internal or external insulation layer of the heating element; Improper installation, insufficient maintenance, and other factors may also cause short circuit faults.
Performance: The current of the heating element increases abnormally after being powered on, causing the equipment to trip or the fuse to burn out.
Heating element overheating
Reason: The heating element has been operating under overload for a long time, resulting in poor heat dissipation and overheating; Control system failures, high ambient temperatures, and other factors may also cause heating elements to overheat.
Performance: If the surface temperature of the heating element is too high, it may cause a fire or equipment damage.

3. Temperature control malfunction
Excessive temperature fluctuations
Reason: Heating element aging, damage, or control system malfunction may cause excessive temperature fluctuations.
Performance: Unstable temperature inside the furnace affects the annealing effect of the material.
The temperature rises too slowly
Reason: Insufficient heating power, aging insulation materials, or accumulation of dust inside the electric furnace may cause the temperature to rise too slowly.
Performance: The temperature inside the furnace cannot reach the set value for a long time, which affects production efficiency.
Temperature too high
Reason: Control system malfunction, temperature sensor damage, or misoperation may cause excessive temperature.
Performance: If the temperature inside the furnace exceeds the set value, it may cause material damage or equipment failure.

4. Mechanical structural failure
The lifting system is malfunctioning
Reason: Mechanical failures such as gear wear, loose or broken chains, and damaged bearings may cause the lifting system to malfunction; Electrical faults such as motor failure, limit switch failure, and circuit failure may also cause the lifting system to malfunction.
Performance: The furnace body cannot be lifted or lowered normally, affecting the use of the equipment.
Poor sealing of furnace door
Reason: Aging, damage, or improper installation of the furnace door sealing strip may lead to poor sealing of the furnace door.
Performance: Leakage of atmosphere inside the furnace, affecting the annealing effect and equipment safety.

5. Vacuum system malfunction (if applicable)
vacuum pump failure
Reason: Vacuum pump wear, blockage, or power failure may cause the vacuum pump to malfunction.
Performance: The vacuum degree inside the furnace cannot reach the set value, which affects the annealing effect.
vacuum leak
Reason: Poor sealing of the furnace body, rupture of vacuum pipelines, or damage to valves may cause vacuum leakage.
Performance: The vacuum degree inside the furnace decreases, affecting the annealing effect and equipment safety.