Copper Ingot Casting Machine
Copper Ingot Casting
1. Equipment Introduction
2. Working Environment and Parameters
3. Brief Description of Equipment Structure
4. Equipment Installation Instructions
5. Maintenance and Safe Operation
Part I Equipment Introduction
The copper ingot casting line is an automated production line for continuous casting of ordinary copper ingots. Working process: The molten copper liquid comes out of the smelting furnace, is poured into the horizontal casting mold through the chute and distributor, cools and solidifies in the casting mold, and is transported to the end of the equipment and then demolded. The operator can collect the copper ingot.
The copper ingot casting line has good stability, high efficiency, easy operation and simple maintenance. Part II Working Environment and Parameters
(1) Ambient temperature: maximum temperature 55°C; minimum temperature: -25°C
(2) Working environment: indoor.
(3) Raw materials for equipment production: copper and copper alloy melt.
(4) Melting copper temperature: 1100-1120℃
(5) Power supply: 380V±5%; three-phase AC: within 60Hz±1%.
Part III: Brief description of equipment structure
The 30kg copper ingot casting line is a fixed equipment. The molten copper from the furnace flows into the distributor through the copper chute and the casting chute, so that the molten copper is evenly injected into the mold installed on the horizontal chain casting machine.
When the mold moves with the chain, the copper ingot in the mold cools and solidifies. When it reaches the end of the mold line, as the mold turns over, the copper ingot in the mold is removed from the mold by its own weight or demolding mechanism and collected. Finally, the casting process of the copper ingot is completed.
The copper ingot casting line adopts a horizontal scale plate straight continuous chain conveyor for transportation.
The main components include:
– Casting frame: including head frame, tail frame, middle frame, pouring system bracket and track. All casting machine parts are made of heavy welded steel structure, and the reinforced welded structure can prevent deformation and vibration during the casting process.
The casting machine head frame includes the bracket of the motor and reducer, and the installed bearing seat and sprocket play the role of power transmission.
The casting machine rear frame is equipped with a chain tensioning device, including 2 conveyor sprockets, supported by 2 heavy-duty tensioning bearings. Tighten the bearing position and change the center distance of the chain head and tail to adjust the chain tension, compensate for the wear of the casting chain, and assist in replacing the chain.
The casting machine middle frame is the main stroke unit of the chain, mold, etc. The cast copper ingot cools and solidifies within this stroke range to prepare for demolding.
The casting system frame of the casting machine is used to install and adjust the driven intermediate wheel and the pouring distributor, and is an important part of the casting machine to complete the pouring work.
The casting machine track is used to support the rollers on the chain, which can not only adjust the stroke of the sprocket, but also improve the wear resistance of the frame and extend the service life.
– Casting chain assembly and copper ingot casting
The casting chain is specially designed based on many years of practical experience, suitable for complex working conditions, and can withstand overloads caused by thermal expansion and corrosion.
The chain is connected by two heavy-duty chain plates through a pin shaft, and the sliding friction is converted into rolling friction through the rotation of the roller, which reduces the friction coefficient and achieves safe and efficient transmission.
The copper ingot casting mold is made of special cast iron material with a smooth surface and precise size. It is a container for receiving molten copper and cooling and solidifying it. It is dedicated to copper ingots, can safely and efficiently clean molten copper, and is durable. The shape and trademark of the mold cavity can be designed and changed according to user requirements.
– Casting machine drive mechanism
This is a power device that enables the casting mold mounted on the chain attachment to perform translational movement, and the translation speed can be adjusted according to the production capacity of the casting machine.
The operator can adjust the speed of the variable frequency motor through the button or knob on the operation panel to obtain any casting speed within the specified range. 2 conveyor sprockets are installed on the power transmission shaft, which is supported by 2 heavy-duty bearing seats, and the bearing seats are bolted to the equipment head frame.
The RV series reducer motor is connected to the transmission shaft, which has a more direct transmission, greater torque, and smoother transmission, ensuring the surface quality of the copper ingot. The reduction motor is installed on one side of the head frame, and the output speed is changed by adjusting the frequency of the inverter to provide various speeds required by the casting process.
– Boat-shaped mold and distributor components.
The copper liquid flows into the distributor through the chute and is injected into the boat-shaped mold through the distributor.
The distributor is installed above the boat-shaped mold through the central axis and the pouring system frame, and the distributor is driven to rotate through the engagement of the coaxial fixed transmission sprocket and the mold chain, so that the rotating movement of the distributor is synchronized with the operation of the mold chain, so that the molten copper flows into the mold continuously, evenly and smoothly, ensuring that the size of the copper ingots produced is uniform.
The boat-shaped mold is installed on the frame of the casting machine. Under normal working conditions, the copper liquid flows into the boat-shaped mold through the distributor, and the copper liquid fills the mold cavity to complete the ingot casting.
The distributor and the boat-shaped mold are made of special wear-resistant and heat-resistant cast iron, which is economical and durable.
Part 4: Equipment Installation Instructions
The copper ingot casting line belongs to the overall assembly conveying equipment. After the equipment is put into use by the manufacturer, the following points should be noted:
1. The ingot casting operation site should be flat, solid, dry, and the road should be unobstructed. The ingot casting line should be leveled to ensure that the equipment runs smoothly after being placed.
2. A chute needs to be set between the ingot casting line furnace and the distributor. The chute is required to be sturdy and reliable, with a certain inclination, and thermal insulation materials are used inside. Since the distributor needs to rotate during operation, a gap must be left between the chute and the distributor, but it must be ensured that the molten copper can flow into the distributor.
3. After the installation and commissioning of each component is completed, the trial run should be carried out in the order of single machine first, linkage later, no-load first, and load later. The chain tensioning device can be adjusted to fine-tune the equipment (the trial run experiment has been carried out before leaving the factory) to ensure that the ingot casting line runs smoothly.
Part V: Maintenance and safe operation
Maintenance: 1. Bearings and tracks of the headstock with seat: regularly add lubricating oil to the bearing seat and clean the track.
2. Rear frame bearing and seat rail: regularly add lubricating oil to the bearing seat and clean the rail.
3. Intermediate frame: clean the rail.
4. Continuous casting machine reducer: regularly replace lubricating oil (8-12 months, gear oil).
Safe operation: 1. The tools used before operation must be fully dried and preheated to prevent molten copper from splashing and injuring people.
2. All labor protection equipment must be worn before work.
3. When the continuous casting machine is running, it is forbidden to place objects on the mold.
4. When jogging, it must be confirmed that there is no one on the road before continuing to operate.
5. Copper ingots that have not been demolded should be knocked out and pulled out in time.
6. When cleaning copper slag, tools should be used. It is forbidden to touch various heat conductors, ground copper ingots, etc. with bare hands to prevent burns.
7. Tools and items not related to the work must not be piled up at the work site.
8. The site must be kept clean so that the site can be cleaned up after the work is completed.