Automatic loading and unloading device of molten aluminum two-man ladle vehicle

Abstract

The invention discloses a molten aluminum two-man ladle vehicle self-loading and unloading device which comprises a two-man ladle vehicle, and the two-man ladle vehicle is provided with a two-man ladle support used for bearing and fixing a molten aluminum two-man ladle, and the two-man ladle support is of an independent modular structure; the hydraulic self-lifting executing mechanism is arranged on the ladle car and used for driving the ladle support to carry out loading and unloading movement relative to the car frame; the hydraulic self-lifting executing mechanism comprises a lifting frame, the lifting frame is hinged to one end of a connecting rod mechanism, and the other end of the connecting rod mechanism is hinged to a ladle car frame. One end of the hydraulic driving unit is connected with the two-man ladle vehicle frame, and the other end of the hydraulic driving unit is connected with the two-man ladle vehicle frame. Dependence of a crown block is eliminated, the transfer efficiency is greatly improved, the traditional passive mode of'lifting like a vehicle 'is thoroughly changed by adopting the hydraulic self-lifting technology, and autonomous loading and unloading of the vehicle are achieved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of slag removal equipment, in particular to a self-loading and unloading device of an aluminum liquid ladle car. BACKGROUND

[0002] In the production process of the electrolytic aluminum industry, the transfer of aluminum liquid (high-temperature molten aluminum) is a key logistics link connecting the electrolytic workshop and the casting workshop. Currently, a dedicated aluminum liquid ladle car is generally used in the aluminum plant to complete the transportation task of aluminum liquid in cooperation with the multi-functional overhead crane in the workshop.

[0003] The existing typical operation process is as follows: the multi-functional overhead crane of the electrolytic workshop hoists the vacuum ladle filled with aluminum liquid to the corridor platform or directly hoists it onto the aluminum liquid ladle car; the ladle car transports the full ladle to the casting workshop; the overhead crane of the casting workshop unloads the ladle and hoists it to the holding furnace for casting; after the operation is completed, the ladle car transports the empty ladle back to the electrolytic workshop.

[0004] However, through actual application and analysis, this traditional "overhead crane hoisting + vehicle transportation" mode has the following significant technical disadvantages: Serious dependence on overhead crane, low operation efficiency: the multi-functional overhead crane is the core equipment of the electrolytic workshop, which needs to undertake multiple high-frequency process operations such as unloading, replacing anodes, and crust breaking in addition to hoisting the ladle. In actual production, the aluminum liquid ladle car is often forced to be in a standby state for a long time due to the busy overhead crane (the single transfer operation and waiting time often lasts for tens of minutes), and the phenomenon of secondary hoisting and transportation often occurs due to the scheduling problem of the overhead crane. This not only occupies the valuable operation time of the overhead crane, but also seriously restricts the turnover efficiency of aluminum liquid transfer.

[0005] High-altitude hoisting operation has safety hazards: the existing loading and unloading process completely relies on the overhead crane for high-altitude hoisting. The hoisting operation usually requires close cooperation between the ground operator and the overhead crane driver. In the process of hoisting the ladle filled with high-temperature aluminum liquid, any operation error or equipment failure can cause serious personal injury accidents, and the safety risk level is high.

[0006] Poor matching of vehicle chassis, high center of gravity: most of the aluminum liquid ladle cars used in the industry are modified using ordinary highway truck chassis. The load platform height of such chassis is usually above 1450mm, which leads to a high center of gravity of the whole vehicle after loading the ladle. When transporting high-temperature liquid metal on the plant road, the high center of gravity easily causes safety accidents such as vehicle rollover, and the driving stability is poor.

[0007] The mismatch between the power system operating conditions and the actual operating conditions leads to high energy consumption and maintenance costs: Existing vehicles are designed according to highway transportation standards (design speed is usually above 80km / h), while the transportation of molten aluminum within the factory area has strict speed limits (usually not exceeding 20km / h). This results in vehicles operating under uneconomical conditions of "low speed and high RPM" for extended periods (such as prolonged use of low gears), causing huge fuel consumption (often high fuel consumption per 100 kilometers), and severe wear and tear on the engine and transmission system, which not only increases operating costs but also shortens the lifespan of the equipment.

[0008] Existing self-unloading technology has significant limitations: Although some foreign manufacturers have developed AGVs or specific self-unloading vehicles, they are poorly adapted to the strong magnetic field environment unique to electrolysis workshops and are costly; the few existing domestic modification solutions are mostly simple mechanical controls, lacking mature integrated solutions for automated hydraulic lifting and resistance to magnetic field interference.

[0009] In conclusion, developing a self-loading and unloading device for molten aluminum ladles that can eliminate dependence on overhead cranes, achieve automatic loading and unloading on the ground, lower the center of gravity, and adapt to the strong magnetic field environment of electrolysis has become an urgent technical problem to be solved in the aluminum smelting industry. Summary of the Invention

[0010] The purpose of this invention is to provide a self-loading and unloading device for aluminum molten ladle carts to solve the problems mentioned in the background art.

[0011] To achieve the above objectives, the present invention provides the following technical solution: A self-loading and unloading device for an aluminum molten ladle cart includes a ladle cart with the following components: a ladle support for supporting and securing the aluminum molten ladle, the ladle support being a modular structure capable of being independently placed on the ground or loaded onto a vehicle; a hydraulic self-lifting actuator mounted on the ladle cart for driving the ladle support to perform loading and unloading movements relative to the vehicle frame; the hydraulic self-lifting actuator includes a lifting frame located at the top of the hydraulic self-lifting actuator for lifting the ladle support from below; one end of the lifting frame is hinged to a linkage mechanism, the other end of the linkage mechanism being hinged to the vehicle frame; and a hydraulic drive unit, one end of the hydraulic drive unit being connected to the vehicle frame and the other end being connected to the lifting frame, driving the lifting frame to rise and fall along the trajectory of the linkage mechanism through telescopic movement.

[0012] Furthermore, the lifting support is provided with a limiting and fixing mechanism, which includes a number of limiting blocks arranged at 120° even intervals on the top surface of the lifting support. The limiting blocks are used to limit the horizontal displacement of the aluminum molten ladle on the support.

[0013] Further, the hydraulic self-lifting actuator is installed at the rear of the frame in an inverted design; the connecting rod mechanism includes two groups of connecting rods respectively located on both sides of the ladle truck frame and parallel to each other and a bent frame located in the middle of the ladle truck frame; the hydraulic drive unit includes hydraulic cylinders arranged on both sides of the ladle truck frame.

[0014] Further, the hydraulic cylinder is further provided with a connecting rod, the two ends of the connecting rod are respectively connected with the hydraulic cylinder and the ladle truck frame, and the hydraulic cylinder and the connecting rod form a triangular support structure.

[0015] Further, the frame of the aluminum ladle truck adopts a Z-shaped structure, and the hydraulic self-lifting actuator is embedded in the low-position platform of the Z-shaped frame.

[0016] Further, it further includes a PLC automatic control system, the PLC automatic control system includes a PLC controller, a touch display terminal arranged in the cab, and a detection sensor group; the PLC controller is electrically connected with the touch display terminal, the detection sensor group and the hydraulic drive unit respectively, for receiving operation instructions and automatically controlling the loading and unloading process.

[0017] Further, the detection sensor group includes displacement sensors respectively installed on the left and right hydraulic cylinders; the PLC controller is configured to execute a synchronous deviation correction logic: real-time comparison of displacement data of left and right hydraulic cylinders, when the synchronous displacement error exceeds a first preset threshold, automatically adjusting the action speed of the hydraulic cylinder for correction; when the synchronous displacement error exceeds a second preset threshold, triggering an alarm and stopping the action.

[0018] Further, the detection sensor group further includes a pressure sensor for monitoring the stress of each support point; the PLC controller is configured to execute a partial load processing logic: when it is detected that the pressure distribution is uneven, indicating that there is a partial load, driving the unilateral hydraulic cylinder to act independently to correct the posture.

[0019] Further, it further includes a safety and emergency auxiliary system, the safety and emergency auxiliary system includes a mechanical safety mechanism and a hydraulic safety circuit; the mechanical safety mechanism is configured to: when the lifting frame rises to the highest point, the connecting rod mechanism reaches the geometric dead point position to form a rest angle lock; the hydraulic safety circuit includes a bidirectional hydraulic lock and an explosion-proof valve installed in the hydraulic cylinder circuit.

[0020] Further, the safety and emergency auxiliary system further comprises an independent emergency unloading module, the module comprising a safety auxiliary motor independent of the vehicle main drive system and an emergency oil pump; the safety auxiliary motor is electrically connected to the power battery of the aluminum ladle crane vehicle, and the output end of the emergency oil pump is connected in parallel to the oil supply circuit of the hydraulic drive unit; the independent emergency unloading module is configured to: when the vehicle main drive system or the main hydraulic system fails, the safety auxiliary motor and the emergency oil pump are driven by the power battery, and the oil circuit is manually switched to drive the hydraulic self-lifting actuator to complete the unloading action.

[0021] Compared with the prior art, the present application has the following advantages: 1. The present application greatly improves the transfer efficiency by getting rid of the dependence on the overhead crane: by adopting the hydraulic self-lifting technology, the traditional passive mode of "crane waiting for lifting" is completely changed, and the autonomous loading and unloading of the vehicle is realized. The vehicle can realize "going with it" in the electrolysis workshop and the casting workshop, effectively eliminating the waiting time caused by the busy or maintenance of the multifunctional overhead crane, and is expected to improve the aluminum water transfer efficiency by more than 30%, while reducing the use frequency and maintenance cost of the overhead crane.

[0022] 2. The present application changes the high-risk "high-altitude lifting" operation into a stable "ground lifting" operation, and personnel are not required to closely cooperate with the hook, thereby fundamentally eliminating the personal injury accidents that may occur during lifting. In addition, through the cooperation of the "Z"-type vehicle frame and the inverted lifting mechanism, the vehicle full-load center of gravity is significantly reduced, solving the problem of high center of gravity and poor driving stability of the traditional modified vehicle, and effectively preventing the risk of rollover.

[0023] 3. For the possible anchor failure of the electric vehicle, the present application creatively designs an emergency unloading module independent of the main drive system. The module directly takes power from the power battery, and when the vehicle loses power or the main hydraulic system is paralyzed, it can still forcibly drive the oil cylinder to complete the unloading. This design solves the industry pain point that the high-temperature aluminum water cannot be unloaded in time when the traditional vehicle fails, which may cause condensation or require the use of large equipment for rescue.

[0024] 4. The introduction of the PLC control system combined with the high-precision displacement sensor realizes the double-cylinder micron-level synchronous correction function. The system can monitor and automatically adjust the lifting posture in real time, effectively preventing the tilting accident caused by unbalanced load or mechanical asynchronization, and greatly improving the convenience and safety of operation compared with the traditional manual or simple mechanical control mode.

[0025] 5. Strong modularity and universality, optimizing the site logistics management: the modular design of the ladle support not only can adapt to different specifications (6t-16t) of the ladle through adjusting the interface, but also realizes the fixed management of the ladle. The idle ladle can be placed neatly on the ground support, no longer occupying the vehicle resources, making the workshop logistics organization more standardized and orderly. BRIEF DESCRIPTION OF DRAWINGS

[0026] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the drawings needed to be used in the embodiments or prior art description will be briefly introduced below. Obviously, the drawings described below relate to only some embodiments of the present application, and other drawings can also be obtained by those skilled in the art without any creative effort on the basis of these drawings.

[0027] Figure 1 Overall structure of the present application Figure One ; Figure 2 Overall structure of the present application Figure Two ; Figure 3 Connection of the lifting truck frame, hydraulic drive unit and connecting rod structure of the present application Figure One ; Figure 4 Connection of the lifting truck frame, hydraulic drive unit and connecting rod structure of the present application Figure Two ; Figure 5 Lifting frame of the present application

[0028] Reference signs: 1-lifting stand; 2-hydraulic self-lifting actuator; 3-lifting frame; 4-lifting truck frame; 5-hydraulic drive unit; 6-limiting block; 7-connecting rod mechanism. DETAILED DESCRIPTION

[0029] The technical solutions in the embodiments of the present application will be described clearly and completely below in combination with the drawings in the embodiments of the present application. Obviously, the described embodiments are only some of the embodiments of the present application, but not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without any creative effort belong to the scope of protection of the present application.

[0030] Embodiment 1. An aluminum water ladle truck self-loading and unloading device aims to solve the problems of serious dependence on overhead crane lifting, low efficiency and large safety hazards in the prior art. The device mainly consists of two parts, i.e. a lifting stand 1 and a hydraulic self-lifting actuator 2.

[0031] The lifting stand 1 is an independent steel structure frame module, which can be placed on the ground of a workshop or be loaded on a vehicle. In order to adapt to different tonnages (such as 6t to 16t) of vacuum ladles in the factory, an adjustable limiting and fixing mechanism is designed on the lifting stand 1. High-strength limiting blocks 6 are welded on the top surface of the lifting stand 1 at three corners (distributed at an angle of 120°), which can effectively prevent the horizontal shaking of the ladle during transportation when the ladle is placed on the lifting stand 1.

[0032] The hydraulic self-lifting actuator 2 is installed on the aluminum water ladle car frame. In this embodiment, the frame is specially designed as a "Z" type low gravity center structure, and the lifting mechanism is installed on the low platform at the rear of the frame. The core of the hydraulic self-lifting actuator 2 includes a lifting frame 3, a linkage mechanism 7 connected with the lifting frame 3, and a hydraulic drive unit 5. The lower end of the hydraulic cylinder of the hydraulic drive unit 5 is fixed to the bottom of the ladle car frame 4, and the upper end of the hydraulic cylinder pushes the lifting frame 3.

[0033] Embodiment 2. The loading and unloading process of this embodiment completely realizes "separation of car and ladle". Loading process: when the aluminum water needs to be transported, the ladle support 1 (on which the ladle full of aluminum water has been placed) is placed on the ground. The driver drives the aluminum water ladle car in reverse, at this time the hydraulic cylinder is in the retracted state, the lifting frame is lowered to the lowest position, and it can smoothly pass under the ladle support. After the vehicle is reversed to the position, the driver starts the "lifting" program, the hydraulic cylinder piston rod is extended, and the lifting frame 3 is pushed up along the trajectory of the linkage mechanism 7, so that the ladle support 1 together with the ladle is stably lifted off the ground. Unloading process: after the vehicle arrives at the destination (such as a casting workshop), reverse operation, the hydraulic cylinder is retracted, the lifting frame 3 is lowered, and the ladle support 1 is stably placed on the ground. Then the vehicle drives away, completing the unloading. The whole process does not need the overhead crane to participate.

[0034] Embodiment 3. This embodiment is equipped with a PLC automatic control system, and a touch display screen is arranged in the cab of the ladle car, which integrates all operation buttons and state displays. A key function of the system is synchronous correction. High-precision displacement sensors are arranged on both left and right hydraulic cylinders. During lifting, the PLC compares the data of both sides in real time. If the height difference between the two sides exceeds 1.0 mm, the system will automatically fine-tune the flow of the lagging side cylinder to catch up. If the height difference abnormally expands to more than 2 mm, the system will immediately alarm and stop forcibly to prevent overturning accidents. In addition, the system also monitors the load distribution through pressure sensors. If it detects that the center of gravity of the ladle deviates (unbalanced load), the system can intelligently control the single cylinder to correct the posture.

[0035] Embodiment 4: Considering the high risk of aluminum water transportation, this embodiment designs multiple safety redundancies: Mechanical locking: through kinematic design, when the lifting frame 3 is lifted to the highest transportation position, the linkage mechanism 7 is just in a "rest angle" state, and the geometric dead point principle is used to achieve natural locking. Even if there is a slight internal leakage of the hydraulic system, it will not cause sliding.

[0036] Hydraulic locking: a bidirectional hydraulic lock and a pipeline explosion-proof valve are arranged on the cylinder circuit. In case of sudden pipe explosion, the cylinder will be automatically locked to prevent the ladle from falling instantly.

[0037] Independent emergency unloading: in view of the possible breakdown (such as engine failure, main pump damage) of the vehicle during transportation, the device is designed with an independent emergency system. The system is composed of a single small motor and an emergency oil pump, which directly takes power from the electric vehicle battery. Even if the vehicle is "stuck", the driver or rescuer can start the emergency system, manually switch the valve, use the battery power to drive the oil cylinder to lift the high-temperature aluminum water package safely to the ground, and facilitate other vehicles to tow away for transportation. This design greatly reduces the risk of aluminum water solidification or the need for large crane rescue due to vehicle failure.

[0038] Obviously, the above only describes some embodiments of the present application, not all embodiments. The above embodiments are not intended to limit the present application, and those skilled in the art can make various changes and modifications to the present application. Any combination, modification, equivalent replacement, improvement and other embodiments made by those skilled in the art within the spirit and principles of the present application shall be within the scope of protection of the present application.

Claims

1. A self-loading and unloading device for a ladle-lifting cart containing molten aluminum, comprising a ladle-lifting cart, characterized in that, The trolley frame is equipped with: a trolley support for supporting and fixing molten aluminum ladles, the trolley support being an independent modular structure; a hydraulic self-lifting actuator, mounted on the trolley, for driving the trolley support to perform loading and unloading movements relative to the frame; the hydraulic self-lifting actuator includes a lifting frame, one end of which is hinged to a linkage mechanism, and the other end of which is hinged to the trolley frame; it also includes a hydraulic drive unit, one end of which is connected to the trolley frame and the other end to the lifting frame.

2. The self-loading and unloading device for aluminum molten ladle cart according to claim 1, characterized in that, The bag-lifting support is provided with a limiting and fixing mechanism, which includes a number of limiting blocks arranged at 120° even intervals on the top surface of the bag-lifting support.

3. The self-loading and unloading device for aluminum molten ladle cart according to claim 1, characterized in that, The hydraulic self-lifting actuator is designed to be installed in reverse at the rear of the lifting cart frame; the linkage mechanism includes two sets of parallel linkages located on both sides of the lifting cart frame and a frame located in the middle of the lifting cart frame; the hydraulic drive unit includes hydraulic cylinders located on both sides of the lifting cart frame.

4. The self-loading and unloading device for aluminum molten ladle cart according to claim 3, characterized in that, The hydraulic cylinder is also equipped with a connecting rod, with the two ends of the connecting rod connected to the hydraulic cylinder and the frame of the lifting cart, respectively, forming a triangular support structure with the hydraulic cylinder and the connecting rod.

5. The self-loading and unloading device for aluminum molten ladle cart according to claim 1, characterized in that, The frame of the lifting cart adopts a Z-shaped structure, and the hydraulic self-lifting actuator is embedded in the low platform of the Z-shaped frame.

6. The self-loading and unloading device for aluminum molten ladle cart according to claim 1, characterized in that, It also includes a PLC automatic control system, which includes a PLC controller, a touch display terminal installed in the cab of the loading and unloading vehicle, and a detection sensor group; the PLC controller is electrically connected to the touch display terminal, the detection sensor group and the hydraulic drive unit respectively, and is used to receive operation commands and automatically control the loading and unloading process.

7. The self-loading and unloading device for aluminum molten ladle cart according to claim 5, characterized in that, The detection sensor group includes displacement sensors respectively installed on the left and right hydraulic cylinders; the PLC controller is configured to execute synchronous correction logic: compare the displacement data of the left and right hydraulic cylinders in real time, and when the synchronous displacement error exceeds the first preset threshold, automatically adjust the action speed of the hydraulic cylinders to correct the deviation; when the synchronous displacement error exceeds the second preset threshold, trigger an alarm and stop the action.

8. The self-loading and unloading device for aluminum molten ladle cart according to claim 5, characterized in that, The detection sensor group also includes a pressure sensor; the PLC controller is configured to execute off-center load processing logic: when uneven pressure distribution is detected, indicating off-center load, the single-sided hydraulic cylinder is driven to move independently to correct the posture.

9. The self-loading and unloading device for aluminum molten ladle cart according to claim 1, characterized in that, It also includes a safety and emergency support system, which includes a mechanical safety mechanism and a hydraulic safety circuit. The mechanical safety mechanism is configured such that when the lifting frame is raised to its highest point, the linkage mechanism reaches the geometric dead point position to form a repose angle lock. The hydraulic safety circuit includes a two-way hydraulic lock and an explosion-proof valve installed in the hydraulic cylinder circuit.

10. The self-loading and unloading device for aluminum molten ladle cart according to claim 8, characterized in that, The safety and emergency assistance system also includes an independent emergency unloading module, which includes a safety auxiliary motor and an emergency oil pump independent of the main drive system of the aluminum molten metal lifting cart. The safety auxiliary motor is electrically connected to the power battery of the aluminum molten metal lifting cart, and the output end of the emergency oil pump is connected in parallel to the oil supply circuit of the hydraulic drive unit. The emergency unloading module is configured to: in the event of a failure in the vehicle's main drive system or main hydraulic system, use the power battery to drive the safety auxiliary motor and emergency oil pump to manually switch the oil circuit to drive the hydraulic self-lifting actuator to complete the unloading action.

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