A vacuum melting and pouring integrated device

Abstract

The present invention relates to the field of vacuum melting and impregnation technology, and specifically to a vacuum melting and pouring integrated device. The device mainly includes a furnace body, a vacuum pumping mechanism, a crucible translation mechanism, and a crucible lifting mechanism. A melting heating sensor and a pouring heating sensor are fixedly arranged inside the furnace body. When the furnace reaches vacuum conditions, the melting and pouring heating sensors operate synchronously to quickly heat the metal material in the melting crucible and the product to be impregnated in the product crucible, respectively, and then pour the metal solution into the product to be impregnated to achieve a vacuum full impregnation effect of the product to be impregnated. The present invention realizes the process of melting metal or alloy to pouring products simultaneously in the furnace body, and also has the advantages of high efficiency, high reliability and safety, which can meet the actual industrial large-scale production needs of the equipment.

Description

Technical Field

[0001] The present invention relates to the technical field of vacuum melting and impregnation, and in particular to a vacuum melting and pouring integrated device. Background Art

[0002] Vacuum melting is a process for heating and melting metals or alloys in a vacuum environment. Vacuum impregnation is a process for filling liquid impregnation substances into the pores of porous or solid materials through a pressure difference under vacuum conditions. Impregnating molten metals or alloys into products can greatly enhance the performance of the materials and eliminate their internal defects. Currently, high-temperature vacuum impregnation equipment is still in an imperfect stage of development, and there is a lack of mature equipment that can effectively meet the needs of actual industrial large-scale production. In the existing technical field, there is no relatively mature equipment to realize the metal or alloy melting and pouring process in a vacuum environment, which undoubtedly increases the complexity, cost and time cycle of production. Summary of the Invention

[0003] In response to the problems existing in the existing high-temperature vacuum melting and impregnation technology field, the present invention provides a vacuum melting and pouring integrated device. Under a high-temperature vacuum environment, the device can simultaneously realize the process of melting metal or alloy to pouring products. At the same time, this equipment integrates high efficiency, high reliability and safety, and can meet the actual industrial large-scale production needs of the equipment.

[0004] In order to achieve the above technical objectives, the present invention adopts the following technical solutions:

[0005] Provided is a vacuum melting and pouring integrated device, comprising a furnace body, a vacuum pumping mechanism, a crucible translation mechanism, and a crucible lifting mechanism;

[0006] A support frame is provided at the bottom of the furnace body, a furnace cover is provided at the top of the furnace body, a smelting heating inductor and a pouring heating inductor are fixedly arranged inside the furnace body, a discharge port is provided at the bottom of the furnace body, a plug valve is provided at the discharge port, the crucible lifting mechanism is provided below the discharge port, the crucible translation mechanism is provided on the side close to the crucible lifting mechanism, a vacuum pipe port is provided on the furnace body, and the furnace body is connected to the vacuum mechanism through the vacuum pipe port;

[0007] A smelting crucible is fixedly provided inside the smelting heating inductor, and the pouring heating inductor is used to accommodate the product crucible transported by the crucible lifting mechanism;

[0008] The crucible translation mechanism includes a moving track, a moving vehicle is provided on the moving track, and one end of the moving track is located at the crucible lifting mechanism.

[0009] Preferably, the vacuum pumping mechanism is composed of several vacuum pumps, which include a sliding valve pump, a Roots pump and a pneumatic butterfly valve. The sliding valve pump and the Roots pump are connected to one end of the pneumatic butterfly valve through a first vacuum pumping tube, and the other end of the pneumatic butterfly valve is connected to the vacuum pipe port of the furnace body through a second vacuum pumping tube.

[0010] Preferably, the furnace cover is provided with a hydraulic lifting device and an observation window.

[0011] Preferably, the smelting heating inductor and the pouring heating inductor are both induction coils wound with copper tubes.

[0012] Preferably, the smelting heating inductor and the pouring heating inductor are both connected to an IGBT medium frequency power supply via electrodes.

[0013] Preferably, the device further comprises a water cooling system, wherein the water cooling system is provided with separate cooling water circulation pipelines for the smelting heating inductor, the pouring heating inductor and the furnace body respectively.

[0014] Preferably, the furnace body adopts a double-layer water sandwich structure.

[0015] Preferably, a tubular fixing structure is provided between the product crucible and the pouring heating inductor.

[0016] Preferably, a funnel structure is overlapped on the top of the tubular fixing structure, and the bottom of the funnel structure extends into the interior of the product crucible.

[0017] Preferably, operating platforms are provided on both sides of the furnace body, and the operating platforms include a frame structure welded from section steel and steel plates.

[0018] Compared with the prior art, the present invention has the following beneficial effects:

[0019] 1) The present invention provides a melting heating inductor and a pouring heating inductor within the furnace body. When the furnace reaches vacuum conditions, the melting heating inductor and the pouring heating inductor operate synchronously, rapidly heating the metal material in the melting crucible and the product to be impregnated in the product crucible, respectively. The rapid melting of the metal material and the rapid heating of the product to be impregnated can be carried out simultaneously. When both reach the process temperature at substantially the same time, the metal solution in the melting crucible is poured onto the product to be impregnated. Subsequently, the crucible of the product to be impregnated is placed in the bell jar with the aid of a pressurized platform for gas pressurization, ultimately achieving a sufficient impregnation effect. The vacuum melting and vacuum pouring processes of the metal material are simultaneously completed within the vacuum furnace body, reducing the complexity, cost, and time cycle of production.

[0020] 2) Furthermore, because the melting and pouring heating sensors operate synchronously, the metal melting process and the heating process of the product to be impregnated are carried out simultaneously under the same vacuum conditions. Independent temperature control by the sensors shortens the melting and pouring process times, effectively improving production efficiency. Furthermore, the present invention utilizes one or more sets of slide valve pumps and Roots pumps to evacuate the furnace, shortening the evacuation process time.

[0021] 3) The present invention utilizes a water-cooling system to provide separate cooling water circulation lines for the smelting heating inductor, pouring heating inductor, furnace body, and other equipment, ensuring that the equipment does not overheat under high-power operation, enabling continuous and stable operation and extending the equipment's service life. Furthermore, the pouring funnel, which is added above the product crucible and is wide at the top and narrow at the bottom, effectively prevents splashing of the high-temperature metal alloy during the pouring process, ensuring production safety and extending the equipment's service life.

[0022] The structural design of the present invention has high reliability, durability and safety, and is very suitable for actual industrial production.

[0023] In summary, the present invention realizes the process of melting metal or alloy and casting products simultaneously in the furnace body, and also has the advantages of high efficiency, high reliability and safety, which can meet the actual industrial large-scale production needs of the equipment. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 This is a schematic structural diagram of a vacuum melting and pouring integrated device according to an embodiment of the present invention;

[0025] In the accompanying drawings, 1. furnace body; 2. furnace cover; 3. smelting heating sensor; 4. pouring heating sensor; 5. support frame; 6. crucible lifting mechanism; 7. moving car; 8. moving track; 9. sliding valve pump; 10. Roots pump; 11. pneumatic butterfly valve; 12. first vacuum pumping tube; 13. second vacuum pumping tube; 14. vacuum pumping nozzle; 15. hydraulic lifting device; 16. observation window; 17. operating table; 18. gate valve; 19. smelting crucible; 20. product crucible; 21. sealed rotary bearing. DETAILED DESCRIPTION

[0026] The following is a combination of the embodiments of the present invention Figure 1 The technical solutions in the embodiments of the present invention are clearly and completely described. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of them. All other embodiments derived by persons of ordinary skill in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0027] In the description of the present invention, it should be understood that the terms "bottom", "one end", "top", "middle", "the other end", "upper", "one side", "top", "inside", "front", "two ends" and the like indicate positions or location relationships based on the attached drawings. Figure 1 The orientation or positional relationship shown is only for the convenience of describing the present invention and simplifying the description, and does not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operate in a specific orientation, and therefore should not be understood as a limitation on the present invention.

[0028] In the present invention, unless otherwise clearly stipulated and limited, the terms "install", "set", "connect", "fix", "screw" and the like should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integrated connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be the internal connection of two elements or the interaction relationship between two elements. Unless otherwise clearly defined, ordinary technicians in this field can understand the specific meanings of the above terms in the present invention according to the specific circumstances.

[0029] Example 1

[0030] The embodiment of the present invention provides a vacuum melting and pouring integrated device, comprising a furnace body 1, a vacuum pumping mechanism, a crucible translation mechanism and a crucible lifting mechanism 6;

[0031] A support frame 5 is provided at the bottom of the furnace body 1, a furnace cover 2 is provided at the top of the furnace body 1, a smelting heating inductor 3 and a pouring heating inductor 4 are fixedly provided inside the furnace body 1, a discharge port is provided at the bottom of the furnace body 1, a gate valve 18 is provided at the discharge port, a crucible lifting mechanism 6 is provided below the discharge port, a crucible translation mechanism is provided on the side close to the crucible lifting mechanism 6, a vacuum nozzle 14 is provided on the furnace body 1, and the furnace body 1 is connected to the vacuum mechanism through the vacuum nozzle 14;

[0032] A smelting crucible 19 is fixedly provided inside the smelting heating inductor 3, and is used to heat and melt the solid metal alloy placed in the smelting crucible. The interior of the pouring heating inductor 4 is used to accommodate the product crucible 20 transported by the crucible lifting mechanism 6, and the pouring heating inductor is used to heat the product in the product crucible.

[0033] The crucible translation mechanism includes a moving track 8 , on which a moving vehicle 7 is provided. One end of the moving track 8 is located at the crucible lifting mechanism. The moving vehicle 7 is used to transport the product crucible 20 to the crucible lifting mechanism 6 .

[0034] Example 2

[0035] The embodiment of the present invention provides a vacuum melting and pouring integrated device, comprising a furnace body 1, a vacuum pumping mechanism, a crucible translation mechanism and a crucible lifting mechanism 6;

[0036] A support frame 5 is provided at the bottom of the furnace body 1 so that the furnace body is positioned at a certain height from the ground. A furnace cover 2 is provided on the top of the furnace body 1. A smelting heating inductor 3 and a pouring heating inductor 4 are fixedly provided inside the furnace body 1. A discharge port is provided at the bottom of the furnace body 1, and a gate valve 18 is provided at the discharge port. A crucible lifting mechanism 6 is provided at the bottom of the furnace body 1 directly below the discharge port, and a crucible translation mechanism is provided on the side close to the crucible lifting mechanism 6. The furnace body 1 is provided with a vacuum pipe port 14, and the furnace body 1 is connected to the vacuum mechanism through the vacuum pipe port 14.

[0037] The smelting heating inductor 3 and the pouring heating inductor 4 are both induction coils wound with copper tubes. A smelting crucible 19 is fixedly installed inside the smelting heating inductor 3, and the interior of the pouring heating inductor 4 is used to accommodate a product crucible 20 transported by a crucible lifting mechanism 6.

[0038] The crucible translation mechanism includes a moving track 8 , on which a moving vehicle 7 is provided. One end of the moving track 8 is located at the crucible lifting mechanism. The moving vehicle 7 is used to transport the product crucible 20 to the crucible lifting mechanism 6 .

[0039] In this embodiment, the vacuum pumping mechanism can be composed of several vacuum pumps, each of which includes a slide valve pump 9, a Roots pump 10, and a pneumatic butterfly valve 11. The slide valve pump 9 and the Roots pump 10 are connected to one end of the pneumatic butterfly valve 11 via a first vacuum pumping tube 12. The other end of the pneumatic butterfly valve 11 is connected to the vacuum pipe opening 14 of the furnace body 1 via a second vacuum pumping tube 13. The pneumatic butterfly valve 11 is provided with a vacuum filter for absorbing impurities during the vacuum pumping process to prevent blockage of the pump body. When the vacuum pumping mechanism is in operation, the slide valve pump 9 is first activated to perform a rough vacuum on the closed furnace body 1. When the vacuum level reaches the pre-vacuum range within which the Roots pump 10 can operate normally, the Roots pump 10 is activated again. The Roots pump 10 then continues to pump air to achieve the required vacuum level. During the vacuum pumping process, the vacuum level can be measured using a composite digital vacuum gauge to accurately control the operation of the slide valve pump 9 and the Roots pump 10. In addition, this vacuum pumping mechanism can also be connected to an exhaust gas collection system. The dust in the vacuum furnace can be directly pumped to the exhaust gas collection system through the vacuum pump and will not enter the oil lubrication chamber of the vacuum system.

[0040] In this embodiment, the furnace cover is provided with a hydraulic lifting device 15 to realize the rotation opening or closing of the furnace cover 2. The furnace cover 2 is provided with an observation window 16, which can be a multi-position rotating observation window. The hydraulic lifting device can directly use the currently more mature hydraulic lifting platform products.

[0041] In this embodiment, both the smelting heating inductor 3 and the pouring heating inductor 4 are connected to an IGBT medium-frequency power supply via electrodes. The ICBT medium-frequency power supply is a static frequency conversion device that uses silicon components and IGBT modules to convert three-phase AC power to a single-phase medium-frequency power supply. The smelting heating inductor 3 can use a 250kW IGBT medium-frequency power supply, while the pouring heating inductor 4 can use a 160kW IGBT medium-frequency power supply. The average power factor of the power supplies reaches above 0.95. In specific implementations, the IGBT medium-frequency power supply can be used for three-phase rectification and conduction, maintaining a high DC voltage. This simplifies operation and facilitates maintenance. The medium-frequency power supply delivers medium-frequency current to the inductors within the furnace via electrodes. The electrodes are then connected to cables from the water cooling system outside the furnace for power. The rectification and frequency conversion control is controlled by a single control panel, resulting in a compact structure. Capacitors and reactors are housed within a power control cabinet, which features an operation panel for overall power control of the device and also houses a switch for the vacuum pump.

[0042] In this embodiment, the device is also equipped with a water cooling system, which provides separate cooling water circulation pipelines for the smelting heating inductor 3, the pouring heating inductor 4, and the furnace body 1. In this embodiment, the induction coils in the smelting heating inductor 3 and the pouring heating inductor 4 are wound with copper tubes, so the cooling water circulation pipeline can be directly connected to the copper tubes. The water flowing inside the copper tubes can remove the heat generated by the electromagnetic coils during operation, ensuring that the coils do not overheat under high-power operation and can operate continuously and stably. In this embodiment, the furnace body 1 adopts a double-layer water sandwich structure, specifically, the inner wall is polished stainless steel (SUS304), and the outer wall is high-quality carbon steel (A3) flange welded into a cylindrical structure. A sealing groove is provided on the flange surface, and an "O" ring vacuum seal is used to seal the cooling water circulation pipeline to achieve furnace cooling. The furnace cover 2 adopts a double-layer water-sandwich head structure and is welded into a whole with a flange. The inner wall is polished stainless steel (SUS304) and the outer wall is high-quality carbon steel. The furnace cover interlayer seal is connected to the cooling water circulation pipeline to achieve cooling of the furnace body.

[0043] In this embodiment, the melting heating inductor 3 comprises a rectangular copper tube wound into an induction coil. A melting crucible 19 is fixedly mounted within the melting heating inductor 3. The melting heating inductor is used to heat and melt the solid metal alloy contained within the melting crucible. The melting heating inductor can be suspended and fixed within the furnace body. In practice, this can be achieved by mounting a conventional suspension bracket on the side or top. The melting heating inductor is fixed to the upper left of the pouring heating inductor to facilitate pouring of the high-temperature molten metal alloy into the product crucible within the pouring heating inductor. The melting heating inductor 3 can be mounted on a sealed slewing bearing 21. The melting heating inductor 3 and the sealed slewing bearing 21 can be connected using a conventional flange connection, such as a welded or bolted flange. When the melting crucible needs to be tilted, it can be manually controlled by an operator using a handle mounted on the sealed slewing bearing to rotate and pour the molten metal alloy. Specifically, the alloy pouring button is set to be pressed. Continuously pressing the pouring switch allows the alloy to flow into the product crucible at a uniform speed. After the switch stops, it pauses for 8-10 seconds, and then the melting reset button is pressed. When it stops, the pouring is completed. This is simple and convenient. The movable baffle at the top of the melting crucible is fixed to ensure the stability of the melting crucible during pouring, making it easy to disassemble and reduce replacement costs.

[0044] In this embodiment, the pouring heating inductor 4 is composed of a rectangular copper tube wound into an induction coil. A product crucible 20 can be placed inside the pouring heating inductor 4. A crucible lifting mechanism 6 can lift the product crucible through the feed port at the bottom of the furnace body 1 into the pouring heating inductor 4 within the furnace body 1, thereby heating the product in the product crucible. In this embodiment, the crucible lifting mechanism employed is conventional technology commonly used in the art. A tubular fixing structure, which can be made of alumina, is provided between the product crucible 20 and the pouring heating inductor 4. This tubular fixing structure provides insulation and ensures that the product crucible can pass smoothly during the upward and downward movement, preventing it from tipping over.

[0045] In this embodiment, a discharge port is provided at the bottom of the furnace body 1, and a gate valve 18 is provided at the discharge port. When the gate valve is opened, the product crucible can be moved into or removed from the furnace body through the crucible lifting mechanism. When the gate valve is closed, the furnace body can be ensured to be a closed space, which can prevent air from entering the furnace body during the pouring process and causing oxidation of the product.

[0046] In this embodiment, a funnel structure may be overlapped on the top of the tubular fixed structure, and the bottom of the funnel structure extends into the interior of the product crucible. When the molten metal alloy is poured into the smelting crucible, the funnel structure with a wide upper mouth and a narrow lower mouth effectively prevents the high-temperature metal alloy liquid from splashing during the pouring process, and can prevent the high-temperature metal alloy liquid from splashing into the insulation layer between the product crucible and the induction coil.

[0047] In this embodiment, an operating table 17 is provided on both sides of the furnace body. The operating table 17 includes a frame structure welded by steel sections and steel plates, which is convenient for the operator to observe the condition of the furnace body through the observation window and operate the opening and closing of the furnace cover. The power control cabinet can also be placed on the operating table to facilitate control of the power supply, etc.

[0048] The following takes the carbon graphite product to be impregnated and the casting material as copper alloy as an example to specifically illustrate the operating process of vacuum melting and impregnation using the present invention: the furnace cover is rotated open by the hydraulic lifting device, the copper alloy block is added to the melting crucible, and then the furnace cover is closed; the carbon graphite product is loaded into the product crucible, and the mobile car transports the product crucible to the crucible lifting mechanism along the moving track, the gate valve at the bottom of the furnace body is opened, and the crucible lifting mechanism lifts the product crucible to the inside of the casting heating sensor in the furnace body. At this time, the gate valve is closed to form a closed space in the furnace body; then the furnace body is evacuated by the cooperation of the sliding valve pump and the Roots pump until the required vacuum degree is reached. Then, the melting crucible and the product crucible are quickly heated by the melting heating inductor and the pouring heating inductor respectively. When the temperature of the copper alloy in the melting crucible reaches the process temperature of 1200℃ or above, it becomes a molten copper alloy. When the carbon graphite product in the product crucible reaches the process temperature of 1300℃ or above, it can be poured. The tilting of the melting crucible is controlled by the rotary bearing, and the copper alloy liquid is poured into the product crucible and covers all the products to be impregnated to achieve sufficient impregnation. Finally, the gate valve is opened, and the product crucible is moved down to the ground with the help of the crucible lifting mechanism, and transported to the subsequent press platform by a mobile vehicle, and the carbon graphite product impregnation is completed by gas pressurization treatment.

[0049] The above description is only an embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent replacements, and improvements made within the scope of the present invention shall be included in the scope of protection of the present invention.

Claims

1. A vacuum melting and pouring integrated device, characterized in that: It includes a furnace body, a vacuum pumping mechanism, a crucible translation mechanism and a crucible lifting mechanism; A support frame is provided at the bottom of the furnace body, a furnace cover is provided at the top of the furnace body, a smelting heating inductor and a pouring heating inductor are fixedly arranged inside the furnace body, a discharge port is provided at the bottom of the furnace body, a plug valve is provided at the discharge port, the crucible lifting mechanism is provided below the discharge port, the crucible translation mechanism is provided on the side close to the crucible lifting mechanism, a vacuum pipe port is provided on the furnace body, and the furnace body is connected to the vacuum mechanism through the vacuum pipe port; A smelting crucible is fixedly provided inside the smelting heating inductor, and the pouring heating inductor is used to accommodate the product crucible transported by the crucible lifting mechanism; The crucible translation mechanism includes a moving track, a moving vehicle is provided on the moving track, and one end of the moving track is located at the crucible lifting mechanism; A tubular fixing structure is provided between the product crucible and the pouring heating inductor; A funnel structure is overlapped on the top of the tubular fixing structure, and the bottom of the funnel structure extends into the interior of the product crucible.

2. The vacuum melting and pouring integrated device according to claim 1, characterized in that: The vacuum pumping mechanism is composed of several vacuum pumps, which include a slide valve pump, a Roots pump and a pneumatic butterfly valve. The slide valve pump and the Roots pump are connected to one end of the pneumatic butterfly valve through a first vacuum pumping pipe, and the other end of the pneumatic butterfly valve is connected to the vacuum pipe port of the furnace body through a second vacuum pumping pipe.

3. The vacuum melting and pouring integrated device according to claim 1, characterized in that: The furnace cover is provided with a hydraulic lifting device and an observation window.

4. The vacuum melting and pouring integrated device according to claim 1, characterized in that: The smelting heating inductor and the pouring heating inductor are both induction coils wound with copper tubes, and are both connected to an IGBT medium-frequency power supply through electrodes.

5. The vacuum melting and pouring integrated device according to claim 4, characterized in that: The smelting heating inductor and the pouring heating inductor are both connected to an IGBT medium frequency power supply through electrodes.

6. The vacuum melting and pouring integrated device according to claim 1, characterized in that: It also includes a water cooling system, which is equipped with separate cooling water circulation pipelines for the smelting heating sensor, the pouring heating sensor, and the furnace body.

7. The vacuum melting and pouring integrated device according to claim 6, characterized in that: The furnace body adopts a double-layer water sandwich structure.

8. The vacuum melting and pouring integrated device according to claim 1, characterized in that: An operating platform is provided on both sides of the furnace body, and the operating platform comprises a frame structure welded by section steel and steel plates.

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