A zinc ingot casting system

Abstract

The application develops a zinc ingot casting system, which is provided with a non-contact height detector and a contact digital height detector on a conveying platform, and an intelligent feeding system is controlled by a jacking oil cylinder to control the lifting of a pushing platform, and a pushing oil cylinder is used to drive a pushing rod and a pushing shovel to push zinc sheets for feeding, and a lifting limiter is arranged at the tail of the pushing rod; the jacking oil cylinder, the lifting limiter, the pushing oil cylinder, the non-contact height detector and the contact digital height detector are controlled by a programmable logic controller; during work, the programmable logic controller controls the lifting of the jacking oil cylinder, detects the single limiting distance through the lifting limiter, and stops working when the set value is reached; then the pushing oil cylinder is started to push the zinc sheets into a discharge hopper.

Description

Technical Field

[0001] This invention relates to the field of non-ferrous metal smelting, specifically to a zinc ingot casting system. Background Technology

[0002] Zinc ingot casting systems commonly employ induction furnaces and ladle casting, such as Figure 1 As shown, the system includes an induction furnace 1, a hopper 9 on top of the furnace 1, and a casting device on one side of the furnace 1. The casting device includes a mold 11 running on a conveyor platform 21, a ladle 10 connected to a motor, and a pouring port at the bottom of the ladle 10 located above the mold 11. This zinc ingot casting system melts zinc sheets in an induction furnace and achieves casting by controlling the rotation of the ladle with a motor.

[0003] However, ladle casting requires a high liquid level in the induction furnace. The zinc sheet slides into the furnace from a height, causing surges and large fluctuations in the liquid level. When the liquid level in the induction furnace is high, molten zinc easily overflows from the ladle position, and the cast zinc ingots have significant positive deviations, resulting in waste. When the liquid level in the induction furnace is low, the cast zinc ingots are not fully filled. Furthermore, when the zinc sheet melts, a large amount of oxide slag floats on the surface of the molten zinc. The oxide slag on the surface of the molten zinc and the surges during feeding are bottlenecks in detecting the actual liquid level in the furnace. Currently, manual feeding is commonly used in China, with manual observation of the fullness of the cast zinc ingots to determine the frequency and amount of feeding. Summary of the Invention

[0004] To address the issues of manual feeding and observation, this invention provides a zinc ingot casting system that determines the feeding frequency and amount based on the actual working conditions of manually observing the fullness of the zinc ingot casting.

[0005] A zinc ingot casting system includes an induction furnace 1, a hopper 9 on top of the induction furnace 1, a mounting base 20 on one side of the induction furnace 1, a ladle 10 movably mounted on the mounting base 20 and connected to a motor; a casting port is provided at the bottom of the ladle 10; a plurality of casting molds 11 are mounted on a conveying platform 21, and the conveying platform 21 is equipped with a non-contact height detector 12 and a contact digital display height detector 14;

[0006] The zinc ingot casting system includes an intelligent feeding system, which comprises a base 15 and a pushing platform 16. The base 15 and the pushing platform 16 are connected by a lifting bracket 3. The lifting bracket 3 is X-shaped and hinged in the middle. One end of the lifting bracket 3 is connected to a hinge seat 17, and the other end of the lifting bracket 3 is equipped with a sliding bolt 4, which slides within a slide rail 18. One end of a lifting cylinder 2 is hinged to the base 15 or the pushing platform 16, and the other end of the lifting cylinder 2 is hinged to the lifting bracket 3. A pushing cylinder 19 is installed on the surface of the pushing platform 16, and a pushing rod 6 passes through the pushing cylinder 19. A pushing shovel 7 is provided at the end of the pushing rod 6, and a lifting limiter 5 is provided at the tail of the pushing rod 6.

[0007] The lifting cylinder 2, lifting limiter 5, pushing cylinder 19, non-contact height detector 12, and contact digital display height meter 14 are controlled by programmable logic controller 13.

[0008] The specific working method of the above zinc ingot casting system is as follows:

[0009] A1: Set the feeding cycle on the programmable logic controller 13 to be equal to the casting cycle of the ladle 10; set the standard thickness h of the liquid zinc ingot measured by the non-contact height detector 12, and the thickness of the qualified zinc ingot is h±δ.

[0010] A2: Set the single-time limit interval of the lifting limiter 5 so that the single-time feeding weight of the zinc sheet 8 is approximately equal to the single-time casting weight;

[0011] A3: Casting begins; the ladle 10 is rotated via a motor to perform the casting.

[0012] A4: The non-contact height detector 12 detects the thickness X of the liquid zinc ingot inside the mold 11 and compares X with h;

[0013] A5: If X≤h-δ, then the intelligent feeding system performs two feedings within a single casting cycle;

[0014] A6: h-δ<X<h+δ, then the intelligent feeding system performs one feeding operation within a single casting cycle;

[0015] A7: If X≥h+δ, then the intelligent feeding system will not perform feeding within a single casting cycle;

[0016] A8: When the mold 11 moves on the conveyor platform to below the contact digital display height meter 14, the liquid zinc ingot inside the mold 11 cools and solidifies. At this time, the height H of the zinc ingot is detected by the contact digital display height meter 14.

[0017] A9: Based on the comparison of H and X, calibrate the zero point h0 of the non-contact height detector 12:

[0018] h0 = HX.

[0019] Advantages of this invention:

[0020] 1. The zinc ingot casting system of the present invention has a simple structure and a high degree of intelligence, realizing continuous and uniform feeding of the induction furnace, reducing product quality problems and energy waste caused by furnace temperature fluctuations;

[0021] 2. When X≤h-δ, it indicates that the liquid level in the induction furnace is low, and two feeding operations are required; when X≥h+δ, it indicates that the liquid level in the induction furnace is high, and no feeding operation is required.

[0022] 3. Because non-contact height detectors are easily affected by high temperatures, dust, and vibrations on site, their working stability is poor. To ensure their stability, it is necessary to calibrate their detection data X: H is detected by a contact digital display height meter, which is used to calibrate the zero position of the non-contact height detector. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the structure of the present invention;

[0024] Figure 2 Schematic diagram of zinc ingot thickness detection according to the present invention;

[0025] Figure 3 Schematic diagram of the lowest position of the intelligent feeding system of this invention;

[0026] Figure 4 This is a schematic diagram of the contact-type digital display altimeter of the present invention;

[0027] Figure 5 This is a flowchart illustrating the working method of the zinc ingot casting system of the present invention;

[0028] In the diagram: 1-Induction furnace; 2-Lifting cylinder; 3-Lifting bracket; 4-Sliding bolt; 5-Lifting limit switch; 6-Push rod; 7-Push shovel; 8-Zinc sheet; 9-Feeding hopper; 10-Ladle; 11-Mold; 12-Non-contact height detector; 13-Programmable logic controller; 14-Contact digital height indicator; 15-Base; 16-Pushing platform; 17-Hinged seat; 18-Slide rail; 19-Pushing cylinder; 20-Mounting base; 21-Conveying platform. Detailed Implementation

[0029] Example 1

[0030] A zinc ingot casting system includes an induction furnace 1, a hopper 9 on the top of the induction furnace 1, a mounting base 20 on one side of the induction furnace 1, a ladle 10 movably mounted on the mounting base 20 and connected to a motor; a casting port is provided at the bottom of the ladle 10; a plurality of casting molds 11 are mounted on a conveying platform 21, and the conveying platform 21 is equipped with a non-contact height detector 12 and a contact digital display height detector 14;

[0031] The zinc ingot casting system includes an intelligent feeding system, which includes a base 15 and a pushing platform 16. The base 15 and the pushing platform 16 are connected by a lifting bracket 3. The lifting bracket 3 is X-shaped and hinged in the middle. One end of the lifting bracket 3 is connected to a hinge seat 17, and the other end of the lifting bracket 3 is equipped with a sliding bolt 4, which slides in a slide rail 18. One end of the lifting cylinder 2 is hinged to the base 15 or the pushing platform 16, and the other end of the lifting cylinder 2 is hinged to the lifting bracket 3. A pushing cylinder 19 is installed on the surface of the pushing platform 16. A pushing rod 6 passes through the pushing cylinder 19. A pushing shovel 7 is provided at the end of the pushing rod 6, and a lifting limiter 5 is provided at the tail of the pushing rod 6.

[0032] The lifting cylinder 2, lifting limiter 5, pushing cylinder 19, non-contact height detector 12, and contact digital display height meter 14 are controlled by programmable logic controller 13.

[0033] During operation, the programmable logic controller 13 controls the lifting cylinder 2 to rise and fall. The lifting limiter 5 detects the single limit distance. After reaching the set value, the lifting cylinder 2 stops working. Then, the pushing cylinder 19 is started to push the zinc sheet 8 into the feeding hopper 9 to complete the feeding. The scoop 10 is rotated by the motor to scoop out the molten zinc and guide it into the casting mold 11 through the casting port to complete the casting.

[0034] The specific working method of the above zinc ingot casting system is as follows:

[0035] A1: Set the feeding cycle on the programmable logic controller 13 to be equal to the casting cycle of the ladle 10; set the standard thickness h of the liquid zinc ingot measured by the non-contact height detector 12, and the thickness of the qualified zinc ingot is h±δ.

[0036] A2: Set the single-time limit interval of the lifting limiter 5 so that the single-time feeding weight of the zinc sheet 8 is approximately equal to the single-time casting weight;

[0037] A3: Casting begins; the ladle 10 is rotated via a motor to perform the casting.

[0038] A4: The non-contact height detector 12 detects the thickness X of the liquid zinc ingot inside the mold 11 and compares X with h;

[0039] A5: If X≤h-δ, then the intelligent feeding system performs two feedings within a single casting cycle;

[0040] A6: h-δ<X<h+δ, then the intelligent feeding system performs one feeding operation within a single casting cycle;

[0041] A7: If X≥h+δ, then the intelligent feeding system will not perform feeding within a single casting cycle;

[0042] A8: When the mold 11 moves on the conveyor platform to below the contact digital display height meter 14, the liquid zinc ingot inside the mold 11 cools and solidifies. At this time, the height H of the zinc ingot is detected by the contact digital display height meter 14.

[0043] A9: Based on the comparison of H and X, calibrate the zero position h0 of the non-contact height detector 12: h0 = HX.

[0044] Taking a 100,000-ton / year zinc ingot casting line as an example, a single zinc ingot weighs 25kg, and four zinc ingots are cast at a time, with a casting cycle of 15s; while a single zinc sheet weighs 50kg and is 30mm thick, and two zinc sheets are needed for each casting.

[0045] A1: Set the feeding cycle to 15s on the programmable logic controller, set the standard thickness h of the liquid zinc ingot measured by the non-contact height detector to 50mm, and the thickness of the qualified zinc ingot to 50mm±2mm.

[0046] A2: Set the single limit interval of the lifting limit device to 60mm;

[0047] A3: Casting begins, automatic feeding;

[0048] A4: Non-contact height measuring instrument for measuring zinc ingot thickness X;

[0049] If A5:X≤48mm, the intelligent feeding system will perform two feedings within a single casting cycle;

[0050] A6: 48mm < X < 52mm, then the intelligent feeding system will perform one feeding operation within a single casting cycle;

[0051] If A7:X≥52mm, the intelligent feeding system will not perform feeding within a single casting cycle;

[0052] A8: Contact digital display height gauge for detecting zinc ingot height H;

[0053] A9: Based on the comparison between H and X, calibrate the zero point h0 of the non-contact height detector:

[0054] h0 = HX.

[0055] If the non-contact height gauge measures a zinc ingot thickness X = 50 mm, while the contact digital height gauge measures a zinc ingot height H = 51 mm, then the zero point h0 of the non-contact height gauge should be calibrated to 1 mm.

[0056] In conclusion, the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A zinc ingot casting system, characterized in that: The zinc ingot casting system includes an induction furnace, a hopper on top of the furnace, a mounting base on one side of the furnace, a ladle movably mounted on the mounting base and connected to a motor; a casting port at the bottom of the ladle; and several casting molds mounted on a conveying platform, which is equipped with a non-contact height detector and a contact digital height detector. The zinc ingot casting system includes an intelligent feeding system, which comprises a base and a pushing platform. The base and the pushing platform are connected by a lifting bracket, which is X-shaped and hinged in the middle. One end of the lifting bracket is connected to a hinged seat, and the other end of the lifting bracket is fitted with a sliding bolt that slides within a slide rail. One end of a lifting cylinder is hinged to the base or the pushing platform, and the other end of the lifting cylinder is hinged to the lifting bracket. A pushing cylinder is mounted on the surface of the pushing platform, and a pushing rod passes through the pushing cylinder. A pushing shovel is provided at the end of the pushing rod, and a lifting limiter is provided at the tail of the pushing rod. The lifting cylinder, lifting limiter, pushing cylinder, non-contact height detector, and contact digital display height meter are controlled by a programmable logic controller.

2. The method of using the zinc ingot casting system as described in claim 1, characterized in that: The specific working method is as follows: A1: Set the feeding cycle on the programmable logic controller (13) to be equal to the casting cycle of the ladle (10); set the standard thickness h of the liquid zinc ingot measured by the non-contact height detector (12), and the thickness of the qualified zinc ingot is h±δ; A2: Set the single limit distance of the lifting limit device (5) so that the single feeding weight of the zinc sheet (8) is approximately equal to the single casting weight; A3: Start casting, and cast by controlling the rotation of the ladle (10) by the motor; A4: The non-contact height detector (12) detects the thickness X of the liquid zinc ingot in the mold (11) and compares X with h; A5: If X≤h-δ, then the intelligent feeding system performs two feedings within a single casting cycle; A6: h-δ<X<h+δ, then the intelligent feeding system performs one feeding operation within a single casting cycle; A7: If X≥h+δ, then the intelligent feeding system will not perform feeding within a single casting cycle; A8: When the mold (11) runs on the conveyor platform to the position below the contact digital display height meter (14), the liquid zinc ingot inside the mold (11) cools and solidifies. At this time, the height H of the zinc ingot is detected by the contact digital display height meter (14). A9: Based on the comparison of H and X, calibrate the zero point h0 of the non-contact height detector (12): h0=HX.

Images