A guide device and gap adjustment method for a deep well hydraulic casting machine

Abstract

The application discloses a guide device and a gap adjusting method for a deep-well hydraulic casting machine, and relates to the technical field of deep-well hydraulic casting machines. The guide device comprises a guide base which is composed of two vertically and parallel arranged high-strength light poles and is fixed to a casting well frame through upper and lower rigid supports; a sliding assembly which is installed on a casting trolley and comprises two groups of slide shoe clamping units, each group of units clamps one light pole through two oppositely arranged semicircular slide shoes; and an eccentric adjusting structure which is installed between the slide shoes and the casting trolley and comprises an eccentric sleeve and a locking device and is used for adjusting the gap between the slide shoes and the light poles. The application further discloses a gap adjusting method of the guide device. The application has the advantages of stable structure, strong eccentric load resistance, high guiding precision and convenient maintenance, and effectively solves the technical problem that the traditional welded guide rail is prone to fatigue welding.

Description

Technical Field

[0001] This invention relates to the field of deep well hydraulic casting machine technology, and in particular to a guide device and clearance adjustment method for a deep well hydraulic casting machine. Background Technology

[0002] Deep-well hydraulic casting machines are key casting equipment for producing large, high-quality copper alloy and aluminum alloy ingots in recent years. With the surge in demand for large-diameter profiles such as large pipes and bars, the requirements for casting machine capacity and ingot specifications are constantly increasing. Against this backdrop, stability and reliability during the casting process are crucial. Currently, the casting trolleys of deep-well hydraulic casting machines mostly use traditional flat guide rails or "V"-shaped guide rails for guidance. Under conditions of increased capacity (such as faster casting speed and larger ingot cross-sections), the load on the casting trolley increases significantly, and it is prone to dynamic off-center loading due to uneven molten metal flow or cooling. Traditional guide rail structures have the following inherent defects: 1. Welded structures are prone to fatigue: Guide rails are typically welded to the rigid frame of the cast well. Under continuous, high-frequency eccentric load impacts and in deep-water operating environments, stress concentration easily occurs at the welded parts of the guide rail (especially at the root), leading to fatigue weld failure. Once the guide rail fails to weld or shifts, it will directly compromise the guiding accuracy.

[0003] 2. Loss of guiding accuracy: After the guide rail is unwelded or deformed, the running trajectory of the casting trolley will deviate, causing the ingot and the crystallizer to be out of sync. This can easily lead to serious defects such as scratches, cracks, eccentricity or even jamming on the surface of the ingot, resulting in low yield and safety hazards.

[0004] 3. Difficult maintenance, affecting continuous production: Repairing the welded guide rail requires stopping the machine and entering the casting well for large-area welding and realignment. The process is complicated, the downtime is long, and it seriously affects the continuity of production.

[0005] Therefore, there is an urgent need for a new type of guiding device that can withstand large loads, resist dynamic off-center load impacts, has high guiding accuracy, is durable, and is easy to maintain, in order to meet the high-capacity and high-quality production needs of modern large-size ingots. Summary of the Invention

[0006] The purpose of this invention is to provide a guiding device and gap adjustment method for a deep well hydraulic casting machine, so as to solve the technical problems of fatigue cracking, loss of guiding accuracy, ingot defects and production interruption caused by traditional welded guide rails in the prior art.

[0007] The technical solution adopted by the present invention to solve the above-mentioned technical problems is: a guiding device for a deep well hydraulic casting machine, comprising: The guide base, fixed on the rigid frame of the casting well, includes two vertically parallel high-strength optical bars, which are symmetrically distributed on both sides of the casting center line and are fixedly connected to the frame through an upper rigid support and a lower rigid support. The sliding assembly, installed on the casting trolley, includes two sets of sliding tile clamping units symmetrically fixed on both sides of the casting trolley. Each set of sliding tile clamping units clamps a light bar by two oppositely arranged semi-circular sliding tiles. An eccentric adjustment structure is installed between the sliding plate and the casting trolley, including an eccentric sleeve and a locking device. The gap between the sliding plate and the guide bar can be adjusted by rotating the eccentric sleeve. After adjustment, it is fixed by the locking device. The calibration structure includes a fixed boom and an adjusting shim set. The fixed boom is connected between the rigid frame and the upper and lower rigid supports. The adjusting shim set is disposed between the fixed boom and the rigid frame and is used to calibrate and fine-tune the parallelism of the two optical bars and their symmetry relative to the casting center line during installation.

[0008] Furthermore, the semi-circular sliding sheet is made of reinforced nylon composite material.

[0009] Furthermore, the reinforced nylon composite material is a modified nylon with added carbon fiber, glass fiber, or solid lubricant.

[0010] Furthermore, the light bar is made of 42CrMo, and its surface is subjected to quenching and tempering treatment and high-frequency quenching, with a hardness of HRC52-55.

[0011] Furthermore, the eccentricity of the eccentric sleeve is 10mm, which enables the gap adjustment between the single-sided sliding tile and the light bar within the range of 0~10mm.

[0012] The present invention also provides a method for adjusting the clearance of a guide device for a deep well hydraulic casting machine, the guide device comprising the following steps: S1. Move the casting trolley to the maintenance station and lock it, so that it is suspended or only subjected to a slight load. S2. After confirming that the casting machine is in a safe stop state, loosen the locking devices on the four eccentric sleeves to release the fixed constraint on the rotation angle of the eccentric sleeves. S3. Rotate each eccentric sleeve in sequence, and adjust repeatedly by feeling, observing the resistance change when the trolley moves slightly, and measuring with a feeler gauge until the gap between each sliding plate and the guide bar is uniformly controlled within the range of 0.05mm to 0.08mm, and all four contact points reach a uniform and appropriate pre-tightening state. S4. After initial tightening of each eccentric sleeve using a method of coarse adjustment followed by fine adjustment, check the gap and contact uniformity. If necessary, perform fine adjustment. After confirming that there are no errors, tighten the locking device in sequence from the middle to both sides until the preset torque value is reached. S5. Run the casting trolley up and down at least three times under no-load conditions, and then run it once under actual casting load conditions to confirm that the operation is smooth, without abnormal friction marks, abnormal noise, jamming or shaking. This completes the gap adjustment.

[0013] Furthermore, in step S1, the slight load state specifically refers to 10% to 20% of the self-weight of the casting trolley, or the pressure of the lower chamber system of the casting cylinder dropping to below 15% of the working pressure.

[0014] Furthermore, in step S4, a method of coarse adjustment followed by fine adjustment is adopted. After the initial tightening of each eccentric sleeve, the gap and contact uniformity are checked. If the gap is inconsistent or the contact is uneven, the eccentric sleeve is finely adjusted by slightly rotating it. After confirming that there are no errors, the locking nuts are finally tightened in sequence from the middle to both sides to reach the preset torque value.

[0015] According to the above technical solution, the beneficial effects of the present invention are: 1. This invention features a robust structure, fundamentally eliminating the risk of weld fatigue failure in the guide rails. Specifically, it replaces the large-area welded guide rails with high-strength optical bars with rigid supports at both ends, fundamentally eliminating the risk of welding fatigue failure and significantly improving structural strength, rigidity, and fatigue resistance. Simultaneously, the symmetrically arranged double optical bars and the four-point engagement (four semi-circular sliding plates) structure constitute a statically indeterminate constraint system, effectively resisting dynamic off-center load moments from all directions, ensuring smooth operation of the trolley under heavy loads and high speeds, without jamming or drifting.

[0016] 2. This invention offers high and durable guiding precision, convenient maintenance, and low cost. Through a unique eccentric sleeve mechanism, the guide clearance can be precisely adjusted online and conveniently to compensate for wear, maintaining near-zero clearance high-precision guidance over the long term, thus ensuring the straightness and surface quality of the ingot. The wear parts are standardized semi-circular sliding plates; replacement simply requires loosening the locking device and removing the old sliding plate for replacement, eliminating the need for hot work, large-scale welding, and prolonged downtime. In particular, the use of a modified nylon sliding plate paired with a steel guide bar creates an ideal "hard-soft" fit. As a replaceable consumable part, the sliding plate effectively protects the more valuable and difficult-to-replace guide bar, significantly reducing overall maintenance costs.

[0017] 3. This invention possesses adaptability to all working conditions and high reliability. The core friction pair of the device (nylon sliding plate-smooth bar) has excellent water vapor resistance and rust prevention properties, and has a sufficient temperature range. It can meet the working conditions of conventional underwater high-speed casting, and can also fully adapt to the needs of special production processes such as slow cooling of "red ingots". This realizes the universality, durability and high reliability of the guiding device across the entire process range. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall structure of the guiding device of the present invention applied to a deep well hydraulic casting machine; Figure 2 This is a schematic diagram of the sliding component structure; Figure 3 This is a magnified decomposition diagram of the eccentric adjustment structure.

[0019] The markings in the diagram are: 1. Upper rigid support, 2. Smooth bar, 3. Fixed boom, 4. Casting trolley, 5. Sliding assembly, 51. Sliding pad, 52. Pad seat, 53. Sliding pad shaft, 6. Eccentric adjustment structure, 61. Locking nut, 62. Eccentric sleeve, 7. Casting cylinder, 8. Lower rigid support. Detailed Implementation

[0020] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0021] The structures, proportions, sizes, etc., shown in the accompanying drawings of this specification are only for the purpose of assisting those skilled in the art in understanding and reading the content disclosed in the specification, and are not intended to limit the conditions under which the present invention can be implemented. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in the proportions, or adjustments to the size, without affecting the effects and objectives that the present invention can produce, should still fall within the scope of the technical content disclosed in the present invention.

[0022] like Figure 1-3 As shown, a guiding device for a deep well hydraulic casting machine includes: The guide base, fixed on the casting well frame, consists of two vertically parallel high-strength light bars 2. The two light bars 2 are symmetrically distributed on both sides of the casting center line and are fixedly connected to the frame through the upper rigid support 1 and the lower rigid support 8. It should be noted that the material of the light bar 2 is 42CrMo, and the surface is tempered and high-frequency quenched, with a hardness of HRC52-55.

[0023] The sliding component 5 is installed on the casting trolley 4 and includes two sets of sliding tile clamping units symmetrically fixed on both sides of the casting trolley 4. Each set of sliding tile clamping units clamps one of the light bars 2 by two relatively arranged semi-circular sliding tiles 51. Preferably, the semi-circular sliding plate 51 is made of reinforced nylon composite material; the reinforced nylon composite material is modified nylon with added carbon fiber, glass fiber or solid lubricant.

[0024] An eccentric adjustment structure 6, installed between the sliding plate 51 and the casting trolley 4, includes an eccentric sleeve 62 and a locking device. The gap between the sliding plate 51 and the guide bar 2 can be adjusted by rotating the eccentric sleeve 62, and is then fixed by the locking device after adjustment. The eccentricity of the eccentric sleeve 62 is 10mm, enabling gap adjustment between the sliding plate 51 and the guide bar 2 on one side within a range of 0-10mm. The locking device is preferably a locking nut 61.

[0025] The calibration structure includes a fixed boom 3 and an adjusting shim set. The fixed boom 3 is connected between the rigid frame and the upper rigid support 1 and the lower rigid support 8. The adjusting shim set is disposed between the fixed boom 3 and the rigid frame, and is used to calibrate and fine-tune the parallelism of the two optical bars 2 and their symmetry relative to the casting center line during installation.

[0026] The present invention also provides a method for adjusting the gap of the above-mentioned guide device, comprising the following steps: S1. Move the casting trolley 4 to the maintenance position and lock it, so that it is suspended or only subjected to a slight load. Specifically, the slight load state is 10% to 20% of the weight of the casting trolley 4, or the pressure of the lower chamber system of the casting cylinder 7 drops to less than 15% of the working pressure.

[0027] S2. After confirming that the casting machine is in a safe stop state, loosen the locking nuts 61 on the four eccentric sleeves 62 to release the fixed constraint on the rotation angle of the eccentric sleeves 62. S3. Rotate each eccentric sleeve 62 in sequence, and adjust repeatedly by hand, by judging the resistance change when the casting trolley 4 moves slightly, and by measuring with a feeler gauge, until the gap between each sliding plate 51 and the light bar 2 is uniformly controlled within the range of 0.05mm to 0.08mm, and all four contact points reach a uniform and appropriate pre-tightening state. S4. Using a coarse adjustment followed by a fine adjustment, initially tighten each eccentric sleeve 62, then check the gap and contact uniformity. If necessary, perform fine adjustment. After confirming that everything is correct, tighten the locking nuts 61 sequentially from the middle to both sides until the preset torque value is reached. Specifically, the final tightening operation is to tighten the eccentric sleeve locking nuts 61 located in the middle position of the casting trolley 4 first, and then tighten the eccentric sleeve locking nuts 61 located on both sides.

[0028] S5. Run the casting trolley 4 up and down at least three times under no-load conditions, and then run it once under actual casting load conditions to confirm that the operation is smooth, without abnormal friction marks, abnormal noise, jamming or shaking. This completes the gap adjustment. Example 1

[0029] This embodiment uses a deep-well hydraulic casting machine for producing large-sized copper alloy round ingots with an outer diameter of Φ295mm and a length of 6000mm as an example.

[0030] Device configuration and parameters: Light bar 2: Made of 42CrMo, with surface high-frequency quenching after tempering treatment, hardness HRC52-55. Dimensions are: outer diameter 250mm, wall thickness 45mm, length set at 8900mm according to the depth of the casting well, and center distance between the two light bars 2 is 1100mm, symmetrically distributed on both sides of the casting center line.

[0031] Modified Nylon Slip Sheet 51: Made of MC modified nylon (with 30% glass fiber and 5% molybdenum disulfide), the semi-circular slip sheet 51 has an inner diameter of Φ250.2mm (with an initial assembly gap of about 0.2mm), a wall thickness of 25mm, and an axial length of 400mm.

[0032] Eccentric sleeve 62: Made of QAL9-4 material, with an eccentricity of 10mm, which can adjust the gap between the single-sided sliding tile 51 and the light bar 2 within the range of 0~10mm.

[0033] The guide system's load-bearing capacity is designed to be a maximum load (including the total weight of the casting trolley 4, crystallizer, metal ingots, etc.) of 25t.

[0034] Installation and initial calibration: First, the upper rigid support 1 and the lower rigid support 8 are securely connected to the rigid frame of the casting well using high-strength bolts (such as M30, performance grade 8.8). Adjustment shims of various specifications with thicknesses of 0.1mm, 0.2mm, and 0.5mm are installed between the fixed boom 3 and the frame mating surface.

[0035] The two optical bars 2 were hoisted into place and initially tightened. Using a high-precision laser tracker or a long straightedge with a dial indicator, the parallelism and symmetry of the two optical bars 2 were measured and adjusted with the casting center line as the reference. By adding or removing shims, the parallelism error of the two optical bars 2 over their entire length was controlled within 0.1 mm / m, and the overlap error between the central symmetry plane formed by the two optical bars 2 and the casting center line was less than 0.5 mm.

[0036] After calibration, tighten all connecting bolts to the predetermined torque.

[0037] Description of the operation process: Preparation stage: Before casting begins, pre-adjust the guide device according to the aforementioned gap adjustment method. Ensure that the four sliding plates 51 are in uniform contact with the guide bar 2 and that the pre-tightening is appropriate. At this time, a 0.05mm feeler gauge should be used to check the gap at each point; it should not be possible to insert it. The casting trolley 4 can slide smoothly up and down along the guide bar 2 under the drive of the casting cylinder 7, without jamming or significant shaking.

[0038] Casting Stage: Casting begins with molten metal being injected into the crystallizer. The casting trolley 4, pulled by the casting cylinder 7, descends at a set casting speed (e.g., 100 mm / min). During the casting process, which can last for several hours, the solidification and shrinkage of the molten metal may generate dynamic uneven loads, and factors such as casting system vibration can cause eccentric impacts on the casting trolley 4. The dual-screw four-point clamping structure of this invention effectively decomposes and transmits the eccentric torque in any direction to the rigid screw 2, ensuring that the casting trolley 4 always maintains a straight trajectory and that the ingot and crystallizer are concentric. The self-lubricating properties of the modified nylon sliding pad 51 stabilize frictional resistance and reduce drive energy consumption.

[0039] High-temperature adaptation stage: After the ingot has completely solidified, if a "red ingot" slow cooling process is required, the high-temperature ingot will be kept inside the well for several hours. During this period, the ambient temperature inside the well may rise to 80-100℃. The modified nylon sliding sheet material 51 selected in this embodiment can withstand a long-term service temperature of over 120℃, and can still maintain good mechanical properties and dimensional stability under this condition, without the risk of softening and deformation, ensuring the continuous reliability of the guiding function.

[0040] Ingot ejection and resetting stage: After casting and slow cooling are completed, the casting cylinder 7 drives the casting trolley 4 to rise, ejecting the ingot from the crystallizer. During this process, the load changes from heavy to light, which may cause impact. The high-rigidity structure of this guiding device can effectively absorb the impact and maintain a smooth ascent.

[0041] Maintenance and clearance adjustment: After the equipment has run one production cycle (e.g., a total of 100 castings), an inspection revealed that the casting trolley 4 was slightly shaking during the descent.

[0042] Following the adjustment method, first raise the casting trolley 4 to its upper position and lock it to minimize its load. Loosen the locking nuts 61 on the four eccentric sleeves 62. Using a special wrench, fine-tune each eccentric sleeve 62 in turn. During adjustment, the operator should feel the rotational resistance by hand and simultaneously try inserting a 0.08mm feeler gauge between the corresponding sliding plate 51 and the guide bar 2 as a reference. Rotate the eccentric sleeve 62 until the feeler gauge can just be slightly clamped, at which point the gap is approximately 0.05~0.08mm.

[0043] After adjusting the four points in sequence, manually operate the casting cylinder 7 to move the casting trolley 4 up and down several times to confirm that the operation is smooth, without jamming or abnormal noise.

[0044] Finally, tighten all locking nuts 61 to the required torque to complete the online clearance compensation adjustment. The entire process can be completed within 2 hours without stopping the machine to enter the well for complex operations such as welding.

[0045] When the wear of the sliding pad 51 reaches its limit (i.e., the wall thickness is reduced by more than 5mm), simply loosen the locking nut 61, remove the sliding pad shaft 53, and a new modified nylon sliding pad 51 can be replaced. The light bar 2 itself is protected and does not need to be replaced.

[0046] The guiding device and adjustment method described in this invention not only have an advanced and reasonable structural principle, but also exhibit excellent anti-eccentric load performance, high-precision guiding stability, good environmental adaptability and extremely convenient maintenance in the actual large-size ingot production process. It effectively solves the inherent defects of traditional welded guide rails and significantly improves production efficiency and ingot quality.

[0047] It should be noted that the above embodiments are only used to illustrate the present invention, but the present invention is not limited to the above embodiments. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention shall fall within the protection scope of the present invention.

Claims

1. A guiding device for a deep well hydraulic casting machine, characterized in that, include: The guide base, fixed on the rigid frame of the casting well, includes two vertically parallel high-strength optical bars, which are symmetrically distributed on both sides of the casting center line and are fixedly connected to the frame through an upper rigid support and a lower rigid support. The sliding assembly, installed on the casting trolley, includes two sets of sliding tile clamping units symmetrically fixed on both sides of the casting trolley. Each set of sliding tile clamping units clamps a light bar by two oppositely arranged semi-circular sliding tiles. An eccentric adjustment structure is installed between the sliding plate and the casting trolley, including an eccentric sleeve and a locking device. The gap between the sliding plate and the guide bar can be adjusted by rotating the eccentric sleeve. After adjustment, it is fixed by the locking device. The calibration structure includes a fixed boom and an adjusting shim set. The fixed boom is connected between the rigid frame and the upper and lower rigid supports. The adjusting shim set is disposed between the fixed boom and the rigid frame and is used to calibrate and fine-tune the parallelism of the two optical bars and their symmetry relative to the casting center line during installation.

2. The guiding device for a deep well hydraulic casting machine according to claim 1, characterized in that: The semi-circular sliding tile is made of reinforced nylon composite material.

3. A guiding device for a deep well hydraulic casting machine according to claim 2, characterized in that: The reinforced nylon composite material is a modified nylon with added carbon fiber, glass fiber, or solid lubricant.

4. A guiding device for a deep well hydraulic casting machine according to claim 1, characterized in that: The light bar is made of 42CrMo, and its surface is treated with tempering and high-frequency quenching, with a hardness of HRC52-55.

5. A guiding device for a deep well hydraulic casting machine according to claim 1, characterized in that: The eccentricity of the eccentric sleeve is 10mm, which enables the gap adjustment between the sliding tile and the light bar on one side within the range of 0~10mm.

6. A method for adjusting the clearance of a guide device for a deep well hydraulic casting machine, wherein the guide device is the guide device according to any one of claims 1-5, characterized in that, Includes the following steps: S1. Move the casting trolley to the maintenance station and lock it, so that it is suspended or only subjected to a slight load. S2. After confirming that the casting machine is in a safe stop state, loosen the locking devices on the four eccentric sleeves to release the fixed constraint on the rotation angle of the eccentric sleeves. S3. Rotate each eccentric sleeve in sequence, and adjust repeatedly by feeling, observing the resistance change when the trolley moves slightly, and measuring with a feeler gauge until the gap between each sliding plate and the guide bar is uniformly controlled within the range of 0.05mm to 0.08mm, and all four contact points reach a uniform and appropriate pre-tightening state. S4. After initial tightening of each eccentric sleeve using a method of coarse adjustment followed by fine adjustment, check the gap and contact uniformity. If necessary, perform fine adjustment. After confirming that there are no errors, tighten the locking device in sequence from the middle to both sides until the preset torque value is reached. S5. Run the casting trolley up and down at least three times under no-load conditions, and then run it once under actual casting load conditions to confirm that the operation is smooth, without abnormal friction marks, abnormal noise, jamming or shaking. This completes the gap adjustment.

7. The gap adjustment method according to claim 6, characterized in that: In step S1, the slight load state specifically refers to 10% to 20% of the self-weight of the casting trolley, or the pressure of the lower chamber system of the casting cylinder dropping to below 15% of the working pressure.

8. The gap adjustment method according to claim 6, characterized in that: In step S4, a coarse adjustment followed by a fine adjustment is adopted. After the initial tightening of each eccentric sleeve, the gap and contact uniformity are checked. If the gap is inconsistent or the contact is uneven, the eccentric sleeve is finely adjusted by rotating it slightly. After confirming that there are no errors, the locking nuts are finally tightened in sequence from the middle to both sides to reach the preset torque value.

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