Horizontal continuous casting production line and production method of double-hole copper bar of large rotor winding

Abstract

The invention relates to the field of metal processing, and discloses a horizontal continuous casting production line of a double-hole copper bar for a large rotor winding and a production method of the horizontal continuous casting production line. The production line comprises a horizontal continuous casting table, a heat preserving furnace, a crystallizer, a dummy ingot system and a middle cooling structure. The crystallizer comprises a body and a detachable double-hole die, and the middle cooling structure is used for cooling the middle part of the double-hole copper bar. The innovative pulse jet cooling system and the copper bar dummy ingot output are synchronous, and accurate cooling control is achieved. In order to improve the production efficiency, the two crystallizers which are opposite to each other and form an angle of 180 degrees are mounted on the rotating table, and the crystallizers are quickly replaced in cooperation with the annular connecting table, the lifting structure and the transposition structure. The invention further comprises a corresponding production method which covers the whole process from copper liquid injection to double-hole copper bar forming and the operation step of rapid replacement of the crystallizer. The problems of low production efficiency, unstable quality and the like of the double-hole copper bar in the traditional process are effectively solved.

Description

Technical Field

[0001] The present invention relates to the field of metal processing, in particular to the manufacturing technology of core components of large motors, and more specifically, to a horizontal continuous casting production line and a production method of double-hole copper bars for rotor windings of large steam turbine generators. The present invention aims to solve the problems of uneven cooling, low production efficiency, unstable product quality, etc. in the traditional double-hole copper bar production process, and provides an innovative technical solution for the large-scale production of high-quality double-hole copper bars. Background Art

[0002] In large steam turbine generators, the double-hole copper busbar in the rotor winding part is a core component and plays a vital role. It must have a sufficient conductive cross-section and be able to be effectively ventilated and cooled. However, although some domestic manufacturers have been able to independently produce double-hole copper busbars, the existing production process still has many technical difficulties and it is difficult to meet the production needs of high-quality double-hole copper busbars.

[0003] At present, the main production process of double-hole copper busbars uses a horizontal extruder for perforation extrusion. The complete process includes: smelting → casting → round ingot blanking → heating → extrusion → cutting head and tail → drawing → annealing → drawing → annealing → fine drawing → surface inspection → cutting to size → straightening and shaping. This traditional process has the following problems: 1. Unstable product quality: The traditional production method leads to technical problems such as uneven wall thickness, serious eccentricity, and insufficient length that are difficult to solve.

[0004] 2. Low production efficiency: The perforation extrusion method of the horizontal extruder results in a high scrap rate for the extrusion needle and low output, making it impossible to form mass production capacity.

[0005] 3. High cost: Due to complex processes and high equipment losses, production costs remain high.

[0006] 4. Complicated process: The entire production process involves multiple steps, which increases the production cycle and cost.

[0007] 5. High resource consumption: Especially in the three steps of round ingot cutting, heating and extrusion, energy consumption and material loss are relatively large.

[0008] In recent years, with the continuous growth of electricity demand and the transformation of energy structure, the market demand for new high-power generators of 800MW and above has increased rapidly. In order to meet this market trend, promote the localization process of double-hole copper bars for rotor windings of large steam turbine generators, and improve my country's generator equipment manufacturing capabilities, the inventors of this application conducted in-depth market research and technical analysis. It is believed that the introduction of horizontal continuous casting process may be an effective way to solve the existing problems.

[0009] At present, the horizontal continuous casting process is widely used in the processing of copper strips, copper tubes and other products. This process can directly save the three most energy-consuming steps of round ingot cutting, heating and extrusion, which is expected to significantly improve production efficiency and reduce costs. Figure 1 Due to the special structure of the double-hole copper busbar with thin outer wall and thick middle, and the high performance requirements of the product, multiple process parameters need to be precisely controlled during the production process. However, the conventional crystallizer starts cooling from the periphery, which will lead to serious uneven cooling temperature distribution and affect product quality. Therefore, it is still a huge challenge to directly apply the horizontal continuous casting process to the production of double-hole copper busbars.

[0010] On the other hand, in the existing horizontal continuous casting process, one crystallizer can only match one ingot-making line. The crystallizer is easily damaged after working for a long time in a high temperature environment. Once it needs to be repaired, the entire ingot-making line with high cost and large space must be stopped, which seriously affects production efficiency and equipment utilization.

[0011] In view of the above problems, the development of a new horizontal continuous casting process suitable for the production of double-hole copper busbars that can overcome the challenges of existing technologies can not only ensure product quality, but also improve production efficiency, reduce resource consumption, and solve the problem of equipment utilization. It is of great significance to promote the localization and industrial upgrading of core components of large-scale power generation equipment in my country.

[0012] In the prior art, there have been some attempts to improve the quality of copper alloy products by improving the continuous casting process. For example, the authorization announcement number CN 110964943 B discloses a method for producing high-strength copper alloys by semi-continuous casting. This method increases the dispersion strengthening effect of the alloy by adding niobium and manganese elements to the copper-nickel-tin alloy, which is beneficial to improving the strength of the alloy. The use of semi-continuous casting solves the problems of shrinkage and shrinkage defects in model casting and horizontal continuous casting, and also significantly reduces segregation defects and improves production efficiency. However, this method is mainly aimed at high-strength copper alloys and does not solve the cooling problem caused by the special structure of the double-hole copper busbar.

[0013] In addition, application publication number CN 116213661 A discloses a crystallizer and horizontal continuous casting method for preparing tin-phosphor bronze rods. This method achieves structural refinement of tin-phosphor bronze rods by accurately controlling parameters such as casting pitch, pulling speed, pause time, cooling water temperature and pressure, insulation furnace temperature, graphite base temperature, casting frequency, billet outlet temperature, and electromagnetic stirring frequency, thereby basically eliminating the reverse segregation of tin, solving the problem of wire drawing cracking, and significantly improving the tensile strength of the product. This method provides a useful reference in parameter control, but still does not solve the problem of cooling uniformity caused by the special structure of the double-hole copper busbar.

[0014] In view of the above problems, the development of a new horizontal continuous casting process suitable for the production of double-hole copper busbars that can overcome the challenges of existing technologies can not only ensure product quality, but also improve production efficiency, reduce resource consumption, and solve the problem of equipment utilization. It is of great significance to promote the localization and industrial upgrading of core components of large-scale power generation equipment in my country. Summary of the invention

[0015] The purpose of the present invention is to solve the shortcomings of the prior art. The present invention provides a horizontal continuous casting production line for double-hole copper bars for large rotor windings. Through an innovative middle cooling structure and a rapid replacement crystallizer mechanism, the problems of uneven cooling and low efficiency in traditional processes are effectively solved, and the production efficiency and product quality of the double-hole copper bars are significantly improved, providing key technical support for the localization of core components of large-scale power generation equipment and industrial upgrading.

[0016] In order to solve the above problems, the present invention adopts the following solutions: A horizontal continuous casting production line for double-hole copper bars for large rotor windings, comprising: A horizontally arranged continuous casting table; a holding furnace for receiving the molten copper from the smelting furnace and maintaining its temperature; a crystallizer connected to the holding furnace through a molten copper conveying channel; an ingot guide system arranged at the output end of the crystallizer; wherein the crystallizer includes: a main body, having a penetrating sleeve channel and an outwardly protruding mounting portion; a double-hole mold, which is detachable and precisely sleeved on the sleeve channel; the crystallizer also includes a middle cooling structure for cooling the middle part of the double-hole copper bar. Its beneficial effects include: realizing the horizontal continuous casting production of the double-hole copper bar and improving production efficiency. The middle cooling structure solves the problem of insufficient cooling of the middle part of the double-hole copper bar in the traditional process and improves product quality. The detachable double-hole mold design facilitates maintenance and replacement, and improves the flexibility of the production line.

[0017] Preferably, the middle cooling structure comprises: an injection inlet opened on the outer wall of the crystallizer; a plurality of injection outlets opened on the side wall of the mold rod; and a pulse injection assembly capable of spraying cooling medium into the injection inlet. Its beneficial effects include: accurate cooling of the middle part of the double-hole copper bar is achieved through injection cooling. The pulse injection design improves the cooling efficiency and avoids the negative effects that may be caused by continuous cooling.

[0018] Preferably, the ejection outlet is arranged at the rear half of the mold rod. The design of the ejection outlet being arranged at the rear half of the mold rod has the beneficial effect of: specifically solving the problem of increased cooling demand in the middle part when the rear half of the copper liquid solidifies, and effectively preventing the occurrence of quality problems such as center segregation.

[0019] Preferably, the pulse frequency of the pulse jet assembly is synchronized with the cyclic sequence frequency of the double-hole copper bar ingot output, and jet cooling is performed when the double-hole copper bar stops. The design of pulse jet synchronization with the copper bar ingot output has the following beneficial effects: accurate coordination of the cooling process and the production process is achieved. Cooling is performed when the copper bar stops, avoiding cooling interference during the movement process and improving the cooling effect.

[0020] The present invention also provides a horizontal continuous casting production line for double-hole copper bars for large rotor windings, including the horizontal continuous casting production line for double-hole copper bars for large rotor windings according to any one of the above preferred schemes, and also including: a rotating table for installing two crystallizers that are 180° relative to each other; an annular connecting table for connecting the rotating table; a lifting structure for driving the rotating table to lift and lower; a transposition structure for driving the rotating table to rotate to achieve the transposition of the crystallizer. The design of introducing the rotating table, the annular connecting table, the lifting structure and the transposition structure has the beneficial effect of: realizing the rapid replacement of the crystallizer, greatly improving the production efficiency. It allows maintenance of one crystallizer while another is working, reducing downtime.

[0021] Preferably, the transposition structure comprises: a power assembly; a driving gear connected to the power assembly; a transposition gear meshing with the driving gear, wherein the transposition gear is coaxially rotatably connected to the upper end of the annular connecting platform and is coaxially connected to the rotating platform. The beneficial effects thereof include: accurate transposition of the crystallizer is achieved through gear transmission, and the stability and reliability of the transposition process are improved.

[0022] Preferably, the lifting structure comprises: a connecting plate fixedly connected to the lower end of the annular connecting platform; four hydraulic cylinders respectively installed at the four end corners of the lower end of the connecting plate; and an X-shaped support frame connected to the lower end of the connecting plate. Its beneficial effects include: the four-point support design improves the stability of the lifting process. The X-shaped support frame increases the bearing capacity of the entire structure.

[0023] Preferably, the rotating table is located above the continuous casting table, and the distance between the two is greater than the distance between the holding furnace and the crystallizer. The beneficial effect is that the normal insertion of the crystallizer and the holding furnace is ensured, and sufficient space is provided for the replacement operation of the crystallizer.

[0024] Preferably, the transposition structure and the lifting structure are both installed below the continuous casting table, which has the beneficial effects of saving space, optimizing the overall layout, and improving the stability of the entire system.

[0025] Preferably, the gear ratio of the driving gear and the transposition gear is designed to enable the rotary table to accurately rotate 180°. The beneficial effect is that it ensures that the crystallizer can accurately rotate 180° and improves the accuracy of transposition.

[0026] Preferably, the four hydraulic cylinders can move synchronously to ensure that the rotating platform remains horizontal during the lifting process. The beneficial effect is that the rotating platform is ensured to remain horizontal during the lifting process, and the stability and safety of the operation are improved.

[0027] The present invention also provides a method for producing a double-hole copper bar for a large rotor winding, comprising the following steps: S1 injects the molten copper into the holding furnace and maintains its temperature; S2 transports the molten copper from the holding furnace to the crystallizer through the molten copper transport channel; S3 cools the copper liquid in the crystallizer so that it gradually changes from liquid to solid; S4 cools the middle part of the double-hole copper busbar through a middle cooling structure; the middle cooling structure includes: An injection inlet is provided on the outer wall of the crystallizer; A plurality of injection outlets are provided on the side wall of the mold rod; a pulse jet assembly capable of jetting a cooling medium toward the jet inlet; S5 pulls the formed double-hole copper bar out of the crystallizer through the ingot drawing system; Wherein, the step of cooling the middle part of the double-hole copper busbar by the middle cooling structure comprises: The cooling medium is sprayed toward the spray inlet of the outer wall of the crystallizer through the pulse spray assembly; The cooling medium flows through the injection inlet to the injection outlet on the side wall of the mold rod; The cooling medium is sprayed out from the spray outlet to cool the middle part of the double-hole copper busbar.

[0028] Compared with the prior art, the technical solution of the present invention has the following advantages: The horizontal continuous casting production line of double-hole copper bars for large rotor windings of the present invention has achieved many technical breakthroughs and benefit improvements through innovative structural design and process optimization. First, the introduction of the middle cooling structure solves the problem of insufficient cooling of the middle part of the double-hole copper bars in the traditional process, and the design of pulse injection and copper bar ingot output synchronization further optimizes the cooling effect, significantly improving product quality and internal organization uniformity. Secondly, the detachable double-hole mold design combines the innovative configuration of the rotating table, lifting structure and transposition structure to achieve rapid replacement and maintenance of the crystallizer, greatly reducing downtime and improving production efficiency. In addition, the carefully designed transposition mechanism and lifting structure ensure the accuracy and stability of the crystallizer transposition and lifting process, and the optimized spatial layout not only saves space, but also improves the operational convenience and safety of the entire system. In summary, the present invention has achieved remarkable results in improving the production efficiency, product quality, equipment reliability and operational flexibility of double-hole copper bars, and provides strong technical support for the large-scale and high-quality production of double-hole copper bars for large rotor windings, with important practical value and broad application prospects. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the figures required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the figures described below are only some embodiments of the present application. For ordinary technicians in this field, other figures can be obtained based on these figures without paying creative work.

[0030] Figure 1 This is a structural diagram of the product's double-hole copper busbar; Figure 2 It is a structural schematic diagram of the present invention; Figure 3 It is a structural schematic diagram of the crystallizer of the present invention; Figure 4 is a cross-sectional schematic diagram of the crystallizer of the present invention to show the internal structure; Figure 5 It is a structural schematic diagram of the double-hole mold of the present invention; Figure 6 It is a structural schematic diagram of the cooperation between the crystallizer, the rotating structure and the lifting structure of the present invention.

[0031] Figure markings: fastener 001, flange funnel 002, insulation furnace 01, continuous casting table 1, crystallizer 2, main body 20, double-hole mold 21, sleeve channel 22, crystallization channel 021, installation entity 022, second inlet 25, installation part 23, first inlet 24, connecting sleeve 26, mold rod 211, middle cooling structure 3, injection inlet 31, injection outlet 32, pulse injection assembly 33, rotating table 5, transposition structure 6, power assembly 61, driving gear 62, transposition gear 63, lifting structure 7, connecting plate 71, hydraulic cylinder 72, X-shaped support frame 73, annular connecting table 8, ingot guide table 91, ingot guide rod 92. DETAILED DESCRIPTION

[0032] The following will be combined Figure 1-Figure 6 The preferred embodiments of the present invention are described in detail. It should be noted that the following description is only a preferred embodiment of the present invention, rather than a limitation of the present invention. Those skilled in the art should understand that various modifications and variations can be made to the present invention without departing from the spirit and scope of the present invention. The scope of protection of the present invention shall be subject to the attached claims.

[0033] Embodiment 1: In this embodiment, the cross section is made into Figure 1 The double-hole copper busbar of the structure is described as an example, refer to Figure 2-Figure 4 A horizontal continuous casting production line for double-hole copper bars for large rotor windings includes a horizontally arranged continuous casting table 1, a holding furnace 01 (the smelting furnace is not shown in the figure) for receiving the molten copper from the smelting furnace and maintaining its temperature, and a crystallizer 2 connected to the holding furnace 01 through a copper liquid conveying channel. After the molten copper enters the crystallizer 2 from the holding furnace 01 through a precisely controlled flow device, the cooling medium (such as water) circulating through the cooling medium channel inside the crystallizer 2 is rapidly and evenly cooled under the action of the solidified shell formed between the inner wall of the crystallizer 2 and the molten copper, so that the molten copper gradually transforms from a liquid state to a solid state, and finally forms a continuously output double-hole copper bar. The device also includes an ingot guide system arranged at the output end of the crystallizer 2, which is composed of an ingot guide table 91 that can be translated along the output direction of the double-hole copper bar and an ingot guide rod 92 arranged on the ingot guide table 91 and can extend into the crystallizer 2. The ingot guide rod 92 plays a key role in guiding the solidification and forming of the molten copper and controlling the solidification front in the early stage of crystallization, ensuring the consistency of the geometric shape and internal structure of the double-hole copper bar.

[0034] Reference Figure 3The crystallizer 2 includes a body 20 which is mainly a solid structure. The body 20 has a through sleeve channel 22 on a horizontal plane along the mounting surface and near the central area. An outwardly convex mounting portion 23 is provided at one end of the sleeve channel 22. A fastening portion is provided on an upward side of the mounting portion 23 near the free end, and a first inlet 24 for installing copper liquid injection is provided away from the free end. The crystallizer 2 also includes a double-hole mold 21 which is detachable and precisely sleeved on the sleeve channel 22 to form a double-hole copper busbar. The double-hole mold 21 is made of graphite and has a rectangular shape. It is divided into two parts, one part is a large volume crystallization channel 021 with a hollow interior and an open end for the conversion from liquid to solid, and the other part is a small volume installation entity 022 with threads, wherein the installation entity 022 is fitted with the installation part 23 and fixed at the fastening part by a fastener 001, the crystallization channel 021 is precisely inserted into the sleeve channel 22, and a second inlet 25 matching with the first inlet 24 is provided on the crystallization channel 021, and a connecting sleeve 26 is provided between the first inlet 24 and the second inlet 25. A flange funnel 002 is provided on the connecting sleeve 26 to communicate with the copper liquid conveying channel of the insulation furnace 01.

[0035] See also Figure 5 Two mold rods 211 corresponding to the double holes of the double-hole copper bar are arranged in the double-hole mold 21. The mold rod 211 is in the shape of a quadrangular pyramid and has a draft angle that gradually decreases from one end to the other end. The end with a larger cross section of the mold rod 211 (i.e., the end where the copper liquid flows into the crystallizer 2) is set as the front end of the mold rod 211, and the front end of the mold rod 211 is fixedly sealed and connected to the mounting entity 022, or the two are integrated. That is, the direction of the mold rod 211 from the front end to the rear end is consistent with the output direction of the double-hole copper bar, and the direction of the mold rod 211 from the larger end to the smaller end is also consistent with this. Such a design ensures that the flow direction of the copper liquid is consistent with the output direction of the double-hole copper bar, which is conducive to demolding after the copper liquid crystallizes into a solid state and is convenient for the ingot guide operation.

[0036] The body 20 is also provided with a cooling medium channel 27 surrounding the crystallization channel 021, which is used to pass the cooling medium to control the solidification speed and temperature distribution of the copper liquid. The inner wall of the double-hole mold 21 is coated with a special coating that is resistant to high temperatures and has high thermal conductivity to improve the heat conduction efficiency and prevent the copper liquid from adhering. The connecting sleeve 26 and the flange funnel 002 are made of high-temperature resistant alloy materials to ensure good sealing performance under high temperature environments. This design not only optimizes the flow and cooling process of the copper liquid, but also improves the molding quality and production efficiency of the double-hole copper busbar.

[0037] In order to solve the problem of uneven cooling of the middle part of the double-hole copper bar crystallizer 2 due to thin outer walls and thick middle parts, this embodiment is further provided with a middle cooling structure 3 capable of cooling the middle part of the double-hole copper bar. The middle cooling structure 3 works in coordination with the cooling system of the crystallizer 2 to achieve uniform cooling of the outer peripheral wall and the middle part of the double-hole copper bar.

[0038] Specifically, the middle cooling structure 3 includes an injection inlet 31 opened on the outer wall of the crystallizer 2, a plurality of injection outlets 32 opened on the side wall of the mold rod 211 close to another mold rod 211, and a pulse injection assembly 33 capable of spraying the cooling medium into the injection inlet 31. A connected cooling channel is formed between the injection inlet 31 and the injection outlet 32 ​​(the cooling channel can be one in the installation entity 022 and then independently separated in the two mold rods 211; or it can be one independent channel from the installation entity 022 to the two mold rods 211), ensuring that the cooling medium can effectively flow from the injection inlet 31 to the injection outlet 32. It is worth noting that there are two injection inlets 31, which correspond to the positions of the two mold rods 211 respectively. This design ensures uniform cooling of the middle part of the double-hole copper bar.

[0039] The ejection outlet 32 ​​is arranged at the rear half of the mold rod 211. This design takes into account the temperature distribution characteristics of the copper liquid during the crystallization process. Since the temperature of the copper liquid is high in the first half of the crystallizer 2, it mainly relies on peripheral cooling, and in the second half, the copper liquid has solidified, and the cooling of the middle part becomes particularly important. Therefore, the ejection outlet 32 ​​is arranged at the rear half of the mold rod 211, which can more accurately control the cooling rate of the middle part of the double-hole copper bar, and effectively prevent the occurrence of quality problems such as center segregation.

[0040] The pulse jet assembly 33 uses high-frequency pulse technology, the main purpose of which is to allow the cooling medium to pass through the front section quickly to avoid being affected by the high temperature of the front section. This design takes into account the temperature gradient of the double-hole copper busbar during the crystallization process, ensuring that the cooling medium can effectively reach the second half of the area that needs to be cooled. The pause phase in the pulse technology also plays an important role. It not only allows the system to dynamically adjust the injection frequency, pressure and flow rate of the cooling medium according to the real-time monitored temperature data, but also provides the necessary time window for heat transfer and temperature balance.

[0041] This pulse jet design has multiple advantages: First, it can significantly improve the cooling efficiency and achieve directional cooling of the middle part of the double-hole copper bar by precisely controlling the delivery of the cooling medium. Second, pulse jetting effectively prevents the cooling medium from forming a stable steam film on the surface of the mold rod 211, which will hinder heat transfer and reduce the cooling effect. Through periodic jetting and pauses, the potential steam film can be broken, ensuring that the surface of the mold rod 211 always maintains good heat conduction efficiency.

[0042] In addition, the tiny vibrations generated by the pulse jet also have a positive effect on the crystallization process of the copper liquid. This vibration can promote the uniform distribution of solutes in the copper liquid and reduce the occurrence of segregation, thus helping to form a more uniform and dense crystal structure. This not only improves the internal quality of the double-hole copper busbar, but also enhances its mechanical properties and conductive properties.

[0043] By adopting this innovative pulse jet cooling technology, the present invention effectively solves the problem of insufficient cooling and uneven cooling of the middle part of the double-hole copper bar in the traditional continuous casting process. It realizes precise control of the cooling process, which not only ensures that the cooling medium can effectively reach the area that needs cooling, but also avoids the negative impact that may be caused by overcooling. The accuracy and flexibility of this cooling method provide key technical support for the production of high-quality, stable performance double-hole copper bars for large rotor windings.

[0044] In order to further optimize the cooling effect, the injection outlet 32 ​​adopts a special nozzle design, which can atomize the cooling medium into fine water droplets, increase the contact area with the surface of the mold rod 211, and improve the heat exchange efficiency.

[0045] The ingot output process of the double-hole copper bar usually follows the cycle sequence of "pull, push, stop", and this periodic motion mode is crucial to controlling the solidification speed and quality of the copper bar. In order to further optimize the cooling effect, the pulse frequency of the pulse nozzle is synchronized with the frequency of the double-hole copper bar cycle sequence. Specifically, the injection action of the pulse nozzle is precisely set to be performed in the "stop" stage.

[0046] This synchronous design has multiple advantages: Precise cooling: When the double-hole copper busbar is in the "stop" state, the pulse nozzle sprays out the cooling medium. At this moment, the copper busbar is relatively still, which is conducive to the cooling medium acting more evenly on the area that needs cooling, thereby improving the cooling efficiency.

[0047] Avoid interference: During the "pull" and "push" phases, since the copper bar is in motion, spray cooling at this time may cause uneven cooling or unstable cooling medium distribution. By cooling during the "stop" phase, these potential problems can be avoided.

[0048] Precise temperature control: Since the cooling process is synchronized with the copper bar movement cycle, the temperature change within each cycle can be more accurately controlled, which helps to form a more uniform crystal structure.

[0049] Reduce thermal stress: Periodic cooling helps reduce the accumulation of thermal stress inside the copper busbar and reduces the risk of product deformation or cracking during the cooling process.

[0050] In order to improve production efficiency and realize continuous production, the present invention adopts an innovative crystallizer arrangement and replacement mechanism. Figure 6 Specifically, two crystallizers 2 are provided, which are mounted on a rotating table 5 at 180° relative to each other. This design allows one crystallizer to be used for continuous casting while the other crystallizer can be cleaned, maintained or replaced.

[0051] The rotating table 5 is connected to the lifting structure 7 through the annular connecting platform 8. The lifting structure 7 can drive the rotating table 5 to perform lifting and lowering movements, so that the crystallizer 2 can be separated from or plugged into the holding furnace 01. This design ensures that the relative position of the crystallizer 2 and the holding furnace 01 can be accurately controlled when necessary, which is convenient for the start and end of the continuous casting operation.

[0052] The rotating table 5 is also coaxially connected with a transposition structure 6, which can drive the rotating table 5 to rotate, thereby realizing the transposition of the crystallizer 2. This rotation and transposition mechanism allows the two crystallizers 2 to be used alternately quickly, greatly reducing the time required for replacing the crystallizer and improving the overall production efficiency.

[0053] In terms of spatial layout, the rotating table 5 is located above the continuous casting table 1, and the distance between the two is greater than the distance between the holding furnace 01 and the crystallizer 2. This design ensures that there is enough operating space above the continuous casting table 1, so that the crystallizer 2 can be completely separated from the holding furnace 01, thereby realizing the subsequent rotation and transposition operation of the crystallizer 2.

[0054] This innovative design not only enables rapid mold replacement, but also solves the problem of shutting down the traditional continuous casting production line when replacing the mold. By using the two molds alternately, a nearly continuous production process can be achieved, significantly improving production efficiency. At the same time, this design also provides operators with ample space and time to carry out necessary maintenance and adjustments, helping to ensure the stability of product quality and the long-term reliable operation of the equipment.

[0055] The transposition structure 6 and the lifting structure 7 are both installed under the continuous casting table 1. This design not only saves space but also improves the stability of the entire system. Specifically, the transposition structure 6 includes the following key components: Power assembly 61: serves as the power source for the entire transposition system.

[0056] Driving gear 62: directly connected to the power assembly 61, used for transmitting power.

[0057] The shift gear 63 is meshed with the driving gear 62 to achieve accurate power transmission.

[0058] The transposition gear 63 is coaxially connected to the upper end of the annular connecting platform 8 and is also coaxially connected to the rotating platform 5. This design ensures that the power can be effectively transmitted to the rotating platform 5 to achieve accurate transposition of the crystallizer 2. By adjusting the gear ratio of the driving gear 62 and the transposition gear 63, the rotation angle can be accurately controlled to ensure that the two crystallizers 2 can accurately exchange positions.

[0059] The design of the lifting structure 7 is also precise and efficient. It includes the following main parts: The connecting plate 71 is fixedly connected to the lower end of the annular connecting platform 8 and serves as a bearing platform for the entire lifting system.

[0060] Four hydraulic cylinders 72 are respectively installed at the four end corners of the lower end of the connecting plate 71 to provide stable and reliable lifting power.

[0061] X-shaped support frame 73: connected to the lower end of the connecting plate 71 to increase the stability and bearing capacity of the entire structure.

[0062] This design has several significant advantages: Four-point support: The arrangement of the four hydraulic cylinders 72 forms a stable four-point support, ensuring stability and precision during the lifting process. Uniform force: The design of the X-shaped support frame 73 makes the entire structure more evenly stressed, reducing deformation and vibration. Precise control: By precisely controlling the synchronous movement of the four hydraulic cylinders 72, the crystallizer 2 can be smoothly lifted and lowered. High load-bearing capacity: This structural design greatly improves the load-bearing capacity of the entire system and can easily cope with the lifting requirements of heavy crystallizers.

[0063] During the casting process, when the crystallizer 2 fails or needs maintenance, the outlet of the holding furnace 01 can be closed first, and the lifting structure 7 can be started. The hydraulic cylinder 72 and the X-shaped support frame 73 can be used to stably drive the turntable 5 to descend, so that the crystallizer 2 is separated from the holding furnace 01; then the transposition structure 6 is started, and the mutually meshing driving gear 62 and the transposition gear 63 are driven to rotate through the power component 61, and the transposition gear 63 drives the turntable 5 to rotate, so that the crystallizer 2 rotates with the turntable 5, and other crystallizers 2 without faults are rotated to the bottom of the holding furnace 01; then the lifting structure 7 is started again to make it rise, driving the turntable 5 to rise, so that the holding furnace 01 is reinserted into the transposed crystallizer 2.

[0064] During the casting process, if the crystallizer 2 fails or needs maintenance, the specific operation steps are as follows: S1.Safety shutdown: First, close the outlet of the holding furnace 01 and stop the supply of molten copper to ensure safety.

[0065] S2. Crystallizer descends: The lifting structure 7 is started, and the rotating table 5 is smoothly driven down through the synchronous movement of the four hydraulic cylinders 72 under the stable support of the X-shaped support frame 73. This process ensures the safe separation of the crystallizer 2 and the holding furnace 01, while avoiding possible leakage of copper liquid or damage to the equipment.

[0066] S3. Crystallizer replacement: The transposition structure 6 is activated, and the power assembly 61 starts to work, driving the driving gear 62 to rotate. The driving gear 62 and the transposition gear 63 mesh with each other, accurately transmitting the power to the transposition gear 63. Since the transposition gear 63 is coaxially connected to the rotating table 5, the rotating table 5 rotates accordingly, driving the crystallizer 2 to rotate 180°, and accurately positioning the fault-free spare crystallizer 2 directly below the holding furnace 01.

[0067] S4. Crystallizer rises: The lifting structure 7 is started again, this time to make it rise. The hydraulic cylinder 72 extends synchronously, driving the connecting plate 71 and the rotating table 5 to rise. This process allows the spare crystallizer 2 that has just been replaced to be accurately aligned and inserted into the holding furnace 01.

[0068] S5. Resume production: After completing the above steps, the outlet of the holding furnace 01 can be reopened to resume the supply of molten copper and continue the casting production.

[0069] Although the present invention has been disclosed in conjunction with certain embodiments shown and described in detail, various modifications and improvements thereto will be readily apparent to those skilled in the art having benefit of the disclosure herein. Therefore, the spirit and scope of the present invention will not be limited by the foregoing examples, but will be understood in the broadest sense permitted by law.

[0070] All documents cited herein are hereby incorporated by reference in their entirety for all purposes.

Claims

1. A horizontal continuous casting production line for double-hole copper bars for large rotor windings, characterized in that: include: A horizontally arranged continuous casting table (1); A holding furnace (01) for receiving the molten copper from the smelting furnace and maintaining its temperature; A crystallizer (2) connected to the holding furnace (01) via a copper liquid conveying channel; An ingot-starting system arranged at the output end of the crystallizer (2); Wherein, the crystallizer (2) comprises: The body (20) has a through-going sleeve passage (22) and an outwardly protruding mounting portion (23); A double-hole mold (21) is detachable and precisely sleeved on the sleeve channel (22); The crystallizer (2) also includes a middle cooling structure (3) for cooling the middle part of the double-hole copper busbar.

2. The horizontal continuous casting production line of double-hole copper bars for large rotor windings according to claim 1 is characterized in that: The middle cooling structure (3) comprises: an injection inlet (31) provided on the outer wall of the crystallizer (2); A plurality of injection outlets (32) are provided on the side wall of the mold rod (211); A pulse jet component (33) capable of jetting cooling medium toward the jet inlet (31).

3. The horizontal continuous casting production line of double-hole copper bars for large rotor windings according to claim 2 is characterized in that: The injection outlet (32) is arranged at the rear half of the mold rod (211).

4. The horizontal continuous casting production line of double-hole copper bars for large rotor windings according to claim 2 is characterized in that: The pulse frequency of the pulse spray component (33) is synchronized with the cyclic sequence frequency of the double-hole copper bar ingot output, and spray cooling is performed when the double-hole copper bar stops.

5. A horizontal continuous casting production line for double-hole copper bars for large rotor windings, comprising the horizontal continuous casting production line for double-hole copper bars for large rotor windings according to any one of claims 1 to 4, characterized in that: Also includes: A rotating table (5) for mounting two crystallizers (2) which are 180° apart from each other; An annular connecting platform (8) connected to the rotating platform (5); A lifting structure (7) is used to drive the rotating platform (5) to rise and fall; The transposition structure (6) is used to drive the rotating table (5) to rotate so as to achieve the transposition of the crystallizer (2).

6. The horizontal continuous casting production line of double-hole copper bars for large rotor windings according to claim 5, characterized in that: The transposition structure (6) comprises: Power assembly (61); a driving gear (62) connected to the power assembly (61); A transposition gear (63) meshed with the driving gear (62) is coaxially rotatably connected to the upper end of the annular connecting platform (8) and is coaxially connected to the rotating platform (5).

7. The horizontal continuous casting production line of double-hole copper bars for large rotor windings according to claim 5, characterized in that: The lifting structure (7) comprises: A connecting plate (71) fixedly connected to the lower end of the annular connecting platform (8); Four hydraulic cylinders (72) are respectively installed at four end corners of the lower end of the connecting plate (71); An X-shaped support frame (73) is connected to the lower end of the connecting plate (71).

8. A method for producing double-hole copper bars for large rotor windings, characterized in that: The following steps are involved: S1 injects the molten copper into the holding furnace (01) and maintains its temperature; S2 transports the molten copper from the holding furnace (01) to the crystallizer (2) through the molten copper transport channel; S3 cools the copper liquid in the crystallizer (2) so that it gradually transforms from a liquid state to a solid state; S4 cools the middle part of the double-hole copper busbar through a middle cooling structure (3); the middle cooling structure (3) comprises: an injection inlet (31) provided on the outer wall of the crystallizer (2); A plurality of injection outlets (32) are provided on the side wall of the mold rod (211); a pulse jet assembly (33) capable of jetting a cooling medium into the jet inlet (31); S5 pulls the formed double-hole copper bar out of the crystallizer (2) through the ingot drawing system; The step of cooling the middle part of the double-hole copper busbar by the middle cooling structure (3) comprises: Spraying the cooling medium toward the spray inlet (31) of the outer wall of the crystallizer (2) through the pulse spray assembly (33); The cooling medium flows through the injection inlet (31) to the injection outlet (32) on the side wall of the mold rod (211); The cooling medium is sprayed out from the spray outlet (32) to cool the middle part of the double-hole copper busbar.

9. The method for producing double-hole copper busbars for large rotor windings according to claim 8, characterized in that: The method further comprises a crystallizer (2) replacement step, wherein the crystallizer (2) replacement step comprises: The rotating table (5) is driven downward by the lifting structure (7) to separate the crystallizer (2) from the holding furnace (01); The rotating table (5) is driven to rotate by the transposition structure (6), so as to rotate another crystallizer (2) to the bottom of the holding furnace (01); The rotating table (5) is driven to rise by the lifting structure (7), so that another crystallizer (2) is docked with the insulation furnace (01).

10. The method for producing double-hole copper busbars for large rotor windings according to claim 9, characterized in that: The rotating table (5) is provided with two crystallizers (2) which are 180 degrees relative to each other, and the transposition structure (6) drives the rotating table (5) to rotate 180 degrees.

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