Aluminum bar continuous casting apparatus and casting method thereof

Abstract

The application relates to an aluminum bar continuous casting equipment and a casting process thereof, and relates to the technical field of continuous casting equipment.The aluminum bar continuous casting equipment comprises a heating system, a dust collection system, a raw material input system, a rack, a forming system, a pouring system and a separation system, the heating system, the dust collection system and the raw material input system are installed on the rack, the conveying direction of the raw material input system is directed to the heating system, the pouring system is communicated with the heating system, the forming system comprises two rotary forming devices, a material passing channel is formed between the rotary forming devices, both ends of one of the rotary forming devices are provided with baffles, the separation system is arranged between the two rotary forming devices, the separation system comprises a separation rack and a plurality of separation plates, both ends of the separation rack abut against the baffles, the separation plates are slidably installed on the separation rack, the sliding direction of the separation plates is parallel to the rotary axis direction of the rotary forming devices, the separation plates are respectively attached to the rotary forming devices, and the separation plates are directed to the material passing channel, so that the size of the aluminum bar material can be conveniently adjusted.

Description

Technical Field

[0001] This invention relates to the field of continuous casting equipment technology, and in particular to a continuous casting equipment for aluminum bars and its casting process. Background Technology

[0002] Continuous aluminum rod casting equipment is a core piece of equipment in the modern aluminum processing industry. It uses a continuous and automated process to directly cast molten aluminum into rods or billets of specific specifications, achieving efficient, energy-saving, and high-quality production. Its core process begins with online degassing and filtration purification of the molten aluminum. The molten aluminum then flows into a crucial water-cooled crystallizer where it rapidly solidifies and takes shape. It is then pulled out by a traction system and finally cut to length by an automatic sawing device.

[0003] Based on the casting method and product focus, continuous casting machines are mainly divided into several types. Horizontal continuous casting machines are widely used, capable of producing round bars, flat ingots, and shaped bars; they are highly automated and suitable for diverse product needs. Vertical direct cooling casting machines are primarily used to produce large, high-quality extruded billets and rolled slabs, resulting in ingots with a dense and uniform microstructure. For wire rods and other wire products, continuous casting and rolling mills are typically used, seamlessly integrating casting and subsequent rolling processes to produce finished products in a single operation.

[0004] Modern continuous casting equipment is developing towards greater intelligence and efficiency. It commonly employs advanced PLCs (Programmable Logic Controllers) and automation systems to achieve precise closed-loop control of process parameters such as temperature and speed, and integrates processes like automatic stacking and marking. Simultaneously, through structural optimization (such as improvements to cooling and conveying systems) and the adoption of new technologies like electromagnetic stirring, it aims to continuously improve product quality, single-machine capacity, and energy efficiency, while reducing production losses.

[0005] Existing continuous casting equipment has difficulty adjusting the forming size of aluminum bars according to the required production size, and is highly dependent on the subsequent length cutting process, which increases equipment costs. Summary of the Invention

[0006] To overcome the technical defects of the existing technology, the present invention provides a continuous aluminum rod casting equipment and casting process, which can conveniently adjust the size of the aluminum rod.

[0007] The technical solution adopted in this invention is:

[0008] A continuous aluminum rod casting equipment includes a heating system, a dust extraction system, a raw material input system, a frame, a forming system, a pouring system, and a partitioning system. The heating system, dust extraction system, and raw material input system are all mounted on the frame. The dust extraction system is located above the heating system. The raw material input system's conveying direction points towards the heating system. The pouring system is connected to the heating system. The forming system includes two rotary forming devices, forming a material passage between them. One of the rotary forming devices is slidably mounted on the frame via a sliding rail through the passage. Both ends of the rotary forming device are equipped with baffles. The partitioning system is placed between the two rotary forming devices and includes a partition frame and several partition plates. Both ends of the partition frame abut against the baffles. The partition plates are slidably mounted on the partition frame, and their sliding direction is parallel to the rotation axis of the rotary forming devices. The partition plates are respectively attached to the rotary forming devices and point towards the material passage. A crystallization cooling water spray nozzle is provided on the lower side of each partition plate.

[0009] Preferably, the heating system includes a heating furnace body and a plurality of furnace body heating tubes, the furnace body heating tubes are installed inside the heating furnace body, and the casting system is installed on the side wall of the heating furnace body, and the casting system is connected to the inner side wall of the heating furnace body.

[0010] Preferably, the dust collection system has suction ports on the upper side of both the heating system and the casting system.

[0011] Preferably, the raw material input system includes a conveyor sprocket, a conveyor chain, a conveyor chain plate, a conveyor frame, and a conveyor motor. The conveyor frame is installed on the side of the heating system, the conveyor sprocket is rotatably installed on the conveyor frame, the conveyor chain passes around the conveyor sprocket, the conveyor motor is installed on the conveyor frame, the conveyor motor is drivenly connected to the conveyor sprocket, and the conveyor chain plate is installed on the conveyor chain.

[0012] Preferably, the casting system includes an outlet pipe, a casting pipe, a casting funnel, and a casting screw. The bottom of the casting pipe is provided with a casting port. The outlet pipe is installed on the side wall of the heating system and communicates with the inside of the heating system. The casting pipe is installed on the outlet pipe. The casting screw is rotatably installed inside the casting pipe and moves up and down inside the casting pipe. The casting screw is adapted to the casting port. The casting funnel is installed on the lower side of the casting pipe.

[0013] Preferably, the rotary forming device includes a rotary forming roller and a rotary forming frame, the rotary forming roller is rotatably mounted on the rotary forming frame, the rotary forming roller is driven by a rotary forming motor, and the baffles are disposed at both ends of one of the rotary forming rollers.

[0014] Preferably, the separator frame is provided with two separator guide rails, and each separator plate slides along the separator guide rails respectively.

[0015] The continuous casting process for aluminum bars, using continuous casting equipment, includes the following steps:

[0016] S1: The raw material input system sends aluminum raw materials into the heating system;

[0017] S2: The heating system melts the aluminum raw material;

[0018] S3: The gating system pours the molten aluminum material into the molding system;

[0019] S4: The forming system rotates to solidify and form the molten aluminum material, and the separating system separates the molten aluminum material into aluminum rods.

[0020] The beneficial effects of this invention are:

[0021] The heating system, dust extraction system, and raw material input system are all installed on the frame. The heating system is used to melt aluminum raw materials. The dust extraction system is located above the heating system to absorb flue gas. The raw material input system is directed towards the heating system to transport aluminum raw materials. The casting system is connected to the heating system. Molten aluminum raw materials melted by the heating system flow out from the casting system and are then cast onto the forming system.

[0022] The forming system includes two rotary forming devices, forming a material passage between them. One of the rotary forming devices is slidably mounted on the frame via a channel opening rail. When the rotary forming device slides along the channel opening rail, it opens the material passage, facilitating the insertion of the separating system. A pull-out rod is provided on the lower side of the material passage between the two rotary forming devices to provide traction force when the molten material is just pulled out, preventing the molten aluminum material from leaking directly from the lower side of the material passage. The molten aluminum material is cooled and formed within the material passage. Baffles are provided at both ends of one of the rotary forming devices. The separating system is placed between the two rotary forming devices and extends into the material passage area to separate the molten aluminum material within the material passage for forming.

[0023] Specifically, the separation system includes a separation frame and several separation plates. The two ends of the separation frame abut against baffles to fix the lateral position of the separation frame. The separation plates are slidably installed on the separation frame to separate the molten aluminum material in the feed channel. The molten aluminum material is separated by the separation plates to form aluminum rods. The width of the aluminum rods can be adjusted by adjusting the separation plates. The sliding direction of the separation plates is parallel to the rotation axis of the rotary forming device. After the separation plates are adjusted to their positions on the separation frame, they are installed on the separation frame with screws. The separation plates are respectively attached to the rotary forming device to achieve separation in the feed channel. The molten aluminum material passes between adjacent separation plates to form aluminum rods. The separation plates point towards the feed channel to separate the molten aluminum material, thus forming the aluminum rods. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the structure of the present invention.

[0025] Figure 2 This is a schematic diagram of the gating system structure.

[0026] Figure 3 This is a schematic diagram of the molding system structure.

[0027] Figure 4 This is a schematic diagram showing the location of the separation system.

[0028] Figure 5 This is a schematic diagram showing the installation location of the divider frame.

[0029] Figure 6 This is a cross-sectional schematic diagram of the molding system.

[0030] Explanation of reference numerals in the attached figures:

[0031] 1. Heating system;

[0032] 2. Vacuum cleaning system;

[0033] 3. Raw material input system; 31. Conveyor sprocket; 32. Conveyor chain; 33. Conveyor chain plate; 34. Conveyor frame; 35. Conveyor motor;

[0034] 4. Rack;

[0035] 5. Molding system; 51. Rotary molding device; 511. Rotary molding roller; 5111. Baffle; 512. Rotary molding frame; 513. Channel opening slide rail; 52. Material passage; 53. Pull-out rod;

[0036] 6. Gating system; 61. Outlet pipe; 62. Gating pipe; 63. Gating funnel; 64. Gating screw;

[0037] 7. Separation system; 71. Separation frame; 711. Separation guide rail; 72. Separation plate; 721. Crystallization cooling spray nozzle. Detailed Implementation

[0038] The present invention will be further described below with reference to the accompanying drawings:

[0039] like Figure 1 — Figure 6 As shown, this embodiment provides a continuous aluminum rod casting equipment, including a heating system 1, a dust extraction system 2, a raw material input system 3, a frame 4, a forming system 5, a pouring system 6, and a separation system 7. The heating system 1, the dust extraction system 2, and the raw material input system 3 are all installed on the frame 4. The heating system 1 is used to melt aluminum raw materials. The dust extraction system 2 is located above the heating system 1 to absorb flue gas. The raw material input system 3 is directed towards the heating system 1 to transport aluminum raw materials. The pouring system 6 is connected to the heating system 1. The molten aluminum raw materials molten by the heating system 1 flow out from the pouring system 6 and are then poured onto the forming system 5.

[0040] The forming system 5 includes two rotary forming devices 51, forming a material passage 52 between them. One of the rotary forming devices 51 is slidably mounted on the frame 4 via a channel opening slide rail 513. When one of the rotary forming devices 51 slides along the channel opening slide rail 513, it opens the material passage 52, allowing the separating system 7 to extend into it. A pull-out rod 53 is provided on the lower side of the material passage 52 between the two rotary forming devices 51 to provide traction force when the molten material is just pulled out, preventing the molten aluminum material from leaking directly from the lower side of the material passage 52. The molten aluminum material is cooled and formed within the material passage 52. Baffles 5111 are provided at both ends of one of the rotary forming devices 51. The separating system 7 is placed between the two rotary forming devices 51 and extends into the material passage 52 area to separate the molten aluminum material within the material passage 52 for forming.

[0041] Specifically, the separation system 7 includes a separation frame 71 and several separation plates 72. The two ends of the separation frame 71 abut against the baffles 5111 to fix the lateral position of the separation frame 71. The separation plates 72 are slidably installed on the separation frame 71 to separate the molten aluminum material in the feed channel 52. The molten aluminum material is separated by the separation plates 72 to form aluminum rods. The position adjustment of the separation plates 72 can adjust the width of the aluminum rods. The sliding direction of the separation plates 72 is parallel to the rotation axis of the rotary forming device 51. After the separation plates 72 are adjusted to the position of the separation frame 71, the separation plates 72 are installed on the separation frame 71 with screws. The separation plates 72 are respectively attached to the rotary forming device 51 to achieve separation in the feed channel 52. The molten aluminum material passes between adjacent separation plates 72 to form aluminum rods. The separation plates 72 point towards the feed channel 52 to separate the molten aluminum material so that the aluminum rods are formed.

[0042] Specifically, the partition plate 72 has a hollow design and is connected to a water pipe. The partition plate 72 forms two curved surfaces at the position where it is attached to the corresponding rotary forming device 51. These two curved surfaces make the partition plate 72 have a shape that is thinner in the middle and thicker at both ends. A crystallization cooling water nozzle 721 is provided on the lower side of the partition plate 72. The molten aluminum material in this application flows out under the combined traction of the two rotary forming devices 51 and the pull rod 53. The width of the crystallization cooling water nozzle 721 is greater than the minimum distance between the two rotary forming devices 51. The water spray from the crystallization cooling water nozzle 721 causes the molten aluminum material flowing out at the narrowest position between the two rotary forming devices 51 to crystallize quickly, preventing the outer layer of crystallized molten aluminum material from cracking.

[0043] Specifically, the heating system 1 includes a heating furnace body and several furnace body heating tubes. The furnace body heating tubes are electric heating tubes and are installed inside the heating furnace body. The casting system 6 is installed on the side wall of the heating furnace body and is connected to the inner side wall of the heating furnace body to realize the melting of aluminum raw materials.

[0044] Specifically, the dust collection system 2 has suction ports on the upper side of both the heating system 1 and the casting system 6 to achieve air purification.

[0045] Specifically, the raw material input system 3 includes a conveyor sprocket 31, a conveyor chain 32, a conveyor chain plate 33, a conveyor frame 34, and a conveyor motor 35. The conveyor frame 34 is installed on the side of the heating system 1. The conveyor sprocket 31 is rotatably installed on the conveyor frame 34. The conveyor chain 32 passes around the conveyor sprocket 31. The conveyor motor 35 is installed on the conveyor frame 34 and is connected to the conveyor sprocket 31 for transmission. The conveyor chain plate 33 is installed on the conveyor chain 32 to realize the feeding of aluminum raw materials.

[0046] Specifically, the casting system 6 includes an outlet pipe 61, a casting pipe 62, a casting funnel 63, and a casting screw 64. The bottom of the casting pipe 62 is provided with a casting port. The outlet pipe 61 is installed on the side wall of the heating system 1 and communicates with the inside of the heating system 1. The casting pipe 62 is installed on the outlet pipe 61 and is provided with a resistance heating cover to maintain the temperature of the molten aluminum material. The casting screw 64 is rotatably installed inside the casting pipe 62 and rises and falls inside the casting pipe 62. The casting screw 64 is adapted to the casting port. The casting funnel 63 is installed on the lower side of the casting pipe 62 to realize the casting of molten aluminum material.

[0047] Specifically, the rotary forming device 51 includes a rotary forming roller 511 and a rotary forming frame 512. The rotary forming roller 511 is rotatably mounted on the rotary forming frame 512. The rotary forming roller 511 is driven by a rotary forming motor. Baffles 5111 are provided at both ends of one of the rotary forming rollers 511. Molten aluminum material is cooled and formed between the two rotary forming rollers 511.

[0048] Specifically, the separator 71 is provided with two separator rails 711, and each separator plate 72 slides along the separator rails 711 to adjust the size of the aluminum rod material when it is discharged.

[0049] The continuous casting process for aluminum bars, using continuous casting equipment, includes the following steps:

[0050] S1: Raw material input system 3 sends aluminum raw material into heating system 1;

[0051] S2: Heating system 1 melts aluminum raw materials;

[0052] S3: The casting system 6 pours the molten aluminum material into the forming system 5;

[0053] S4: The forming system 5 rotates to solidify and form the molten aluminum material, and the separating system 7 separates the molten aluminum material into aluminum rods.

[0054] The foregoing has shown and described the basic principles and main features of the present invention, as well as its advantages. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the present invention. Various changes and modifications can be made to the present invention without departing from its spirit and scope. All such changes and modifications fall within the scope of the present invention as claimed, which is defined by the appended claims and their equivalents.

Claims

1. A continuous casting equipment for aluminum bars, characterized in that, The system includes a heating system, a dust extraction system, a raw material input system, a frame, a molding system, a casting system, and a separating system. The heating system, dust extraction system, and raw material input system are all mounted on the frame, with the dust extraction system located above the heating system. The raw material input system's conveying direction points towards the heating system. The casting system is connected to the heating system. The molding system includes two rotary molding devices forming a material passageway between them. One of the rotary molding devices is slidably mounted on the frame via a sliding rail through the passageway. Each of the rotary molding devices has baffles at both ends. The separating system is placed between the two rotary molding devices and includes a separating frame and several separating plates. The two ends of the separating frame abut against the baffles, and the separating plates are slidably mounted on the separating frame and fixed to it with screws. The sliding direction of the separating plates is parallel to the rotation axis of the rotary molding devices. The separating plates are respectively attached to… The rotary forming device has a partition plate that dynamically fits into it, forming an aluminum rod forming cavity. A sealing structure is formed at the point where the partition plate fits into the rotary forming device to prevent leakage of molten aluminum material. The partition plate points towards the material passage. A crystallization cooling water nozzle is located on the lower side of the partition plate. The partition frame has two partition guide rails, and each partition plate slides along these rails. The partition plate has a hollow design and is connected to a water pipe. The partition plate forms two curved surfaces at the position where it fits into the corresponding rotary forming device, giving it a shape that is thinner in the middle and thicker at both ends. A crystallization cooling water nozzle is located on the lower side of the partition plate. A pull-out rod is located on the lower side of the material passage to provide traction when the molten aluminum material flows out. The molten aluminum material flows out under the combined traction of the two rotary forming devices and the pull-out rod. The width of the crystallization cooling water nozzle is greater than the minimum distance between the two rotary forming devices.

2. The continuous aluminum rod casting equipment according to claim 1, characterized in that, The heating system includes a heating furnace body and a plurality of furnace body heating tubes. The furnace body heating tubes are installed inside the heating furnace body, and the casting system is installed on the side wall of the heating furnace body and is connected to the inner side wall of the heating furnace body.

3. The continuous aluminum rod casting equipment according to claim 1, characterized in that, The dust collection system has suction ports on the upper side of both the heating system and the casting system.

4. The continuous aluminum rod casting equipment according to claim 1, characterized in that, The raw material input system includes a conveyor sprocket, a conveyor chain, a conveyor chain plate, a conveyor frame, and a conveyor motor. The conveyor frame is installed on the side of the heating system. The conveyor sprocket is rotatably installed on the conveyor frame. The conveyor chain passes around the conveyor sprocket. The conveyor motor is installed on the conveyor frame and is connected to the conveyor sprocket for transmission. The conveyor chain plate is installed on the conveyor chain.

5. The continuous aluminum rod casting equipment according to claim 1, characterized in that, The casting system includes an outlet pipe, a casting pipe, a casting funnel, and a casting screw. The bottom of the casting pipe is provided with a casting port. The outlet pipe is installed on the side wall of the heating system and communicates with the inside of the heating system. The casting pipe is installed on the outlet pipe. The casting screw is rotatably installed inside the casting pipe and moves up and down inside the casting pipe. The casting screw is adapted to the casting port. The casting funnel is installed on the lower side of the casting pipe.

6. The continuous aluminum rod casting equipment according to claim 1, characterized in that, The rotary forming device includes a rotary forming roller and a rotary forming frame. The rotary forming roller is rotatably mounted on the rotary forming frame and is driven by a rotary forming motor. The baffles are disposed at both ends of one of the rotary forming rollers.

7. A continuous casting process for aluminum bars, using the continuous casting equipment for aluminum bars as described in claim 1, characterized in that, Includes the following steps: S1: The raw material input system sends aluminum raw materials into the heating system; S2: The heating system melts the aluminum raw material; S3: The gating system pours the molten aluminum material into the molding system; S4: The forming system rotates to solidify and form the molten aluminum material, and the separating system separates the molten aluminum material into aluminum rods.

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