Highly conductive aluminum busbar and method and apparatus for processing same

Abstract

The application discloses a high-conductivity aluminum busbar and a processing method and device thereof, relates to the aluminum processing technical field, and mainly aims to improve the aluminum busbar quality and reduce the electrolytic aluminum electric energy loss. The main technical scheme of the application is as follows: the high-conductivity aluminum busbar contains the following elements according to the mass percentage: Fe is less than or equal to 0.10%; Si is less than or equal to 0.06%; Cu is less than or equal to 0.001%; Mn is less than or equal to 0.001%; Mg is less than or equal to 0.001%; Zn is less than or equal to 0.005%; Ni is less than or equal to 0.005%; Cr is less than or equal to 0.003%; Ti+V is less than or equal to 0.004%; B is less than or equal to 0.005%; other impurity elements are less than or equal to 0.1%; and Al is greater than or equal to 99.75%.

Description

Technical Field

[0001] This invention relates to the field of aluminum processing technology, and in particular to a high-conductivity aluminum busbar and its processing method and apparatus. Background Technology

[0002] Aluminum busbars are core power transmission components in the electrolytic aluminum process, undertaking the crucial function of transmitting direct current to the anode and cathode of the electrolytic cell.

[0003] According to national standards, conventional aluminum busbars are directly cast from molten aluminum with an AL purity of 99.5% or higher. However, the molten aluminum contains high levels of impurities and gases such as iron, silicon, vanadium, titanium, and hydrogen, resulting in low conductivity of the aluminum busbars. According to current national standards (GB / T5585.2-2018), for electrical copper, aluminum, and their alloy busbars, the resistivity of unannealed aluminum busbars at 20℃ should be ≤0.029 Ωmm² / m and the conductivity (%IACS) ≥59.5%.

[0004] Traditional aluminum melting and casting processes use slag removers for simple slag removal in both the melting furnace and the holding furnace, without hydrogen removal treatment. This leads to pinhole defects in the formed aluminum busbars, resulting in decreased conductivity and mechanical properties. Furthermore, the lack of deep treatment for impurity elements, such as V and Ti in the molten aluminum, causes lattice distortion and electron scattering after solidification, significantly reducing conductivity. Therefore, aluminum busbars produced by traditional processes have higher resistance, lower conductivity, and greater energy loss, making it difficult to meet increasingly stringent industry requirements for energy conservation and carbon reduction. During casting, the slow cooling and solidification rate of the molten aluminum, coupled with uneven cooling, leads to segregation. Summary of the Invention

[0005] In view of this, the present invention provides a high-conductivity aluminum busbar and its processing method and apparatus, the main purpose of which is to improve the quality of the aluminum busbar and reduce the energy loss of electrolytic aluminum.

[0006] To achieve the above objectives, the present invention mainly provides the following technical solutions:

[0007] On one hand, the present invention provides a high-conductivity aluminum busbar, wherein the aluminum busbar contains the following elements by mass percentage: Fe≤0.10%; Si≤0.06%; Cu≤0.001%; ​​Mn≤0.001%; ​​Mg≤0.001%; ​​Zn≤0.005%; Ni≤0.005%; Cr≤0.003%; Ti+V≤0.004%; B≤0.005%; other impurity elements≤0.1%; Al≥99.75%.

[0008] On the other hand, the present invention also provides a method for processing a high-conductivity aluminum busbar, the method comprising the following steps:

[0009] S1 Furnace Loading: Electrolytic aluminum liquid and solid aluminum ingots are used as raw materials and fed into the aluminum melting furnace and stirred. 200-300 kg of solid aluminum ingot cold material is mixed in with each ton of electrolytic aluminum liquid. The solid aluminum ingots are pre-added in a fixed quantity. The purity of both the electrolytic aluminum liquid and the solid aluminum ingots is 99.70%.

[0010] S2 initial refining: Adjust the temperature of the aluminum liquid in the aluminum melting furnace to 730-750℃, carry out powder refining, use a spray gun to inject argon gas and refining agent into the aluminum liquid, and remove the slag on the surface of the aluminum liquid.

[0011] S3 boronizing treatment: The aluminum-boron alloy Al-4B is added to the aluminum liquid, mechanically stirred, and argon gas is used for bottom blowing and coordinated stirring. After standing, the borate at the bottom of the aluminum melting furnace is removed.

[0012] S4 furnace turning: Pour the molten aluminum in the aluminum melting furnace into a holding furnace, leaving a certain amount of molten aluminum in the aluminum melting furnace;

[0013] S5 Refining: Adjust the temperature of the aluminum liquid in the static furnace to 720-740℃, carry out powder refining, use a spray gun to inject argon and refining agent into the aluminum liquid, and remove the slag on the surface of the aluminum liquid.

[0014] S6 online degassing and filtration;

[0015] S7 casting.

[0016] The objectives of this invention and the technical problems it addresses can be further achieved by the following technical measures.

[0017] Optionally, the initial refining time and the refining time are both 15 minutes.

[0018] Optionally, during the boronizing process, the aluminum liquid is allowed to stand for 20-30 minutes.

[0019] Optionally, during furnace turning, the amount of molten aluminum retained in the aluminum melting furnace is 10% of the total capacity of the aluminum melting furnace.

[0020] Optionally, during the casting process, the casting temperature is 680-720℃, the casting speed is 120-400mm / min, the cooling water pressure is 0.25-0.35MPa, and the cooling water temperature is 15-25℃.

[0021] Optionally, during the online degassing and filtration process, the aluminum liquid temperature is reduced by ≤5℃ throughout the process. First, a rotor-type microbubble dispersion process is used to achieve degassing, and then a 50-mesh ceramic filter plate is used to filter the aluminum liquid.

[0022] Optionally, after the refined aluminum liquid flows out of the settling furnace, the temperature of the aluminum liquid is adjusted to 710-720℃, and aluminum-titanium-boron wire is added at the outlet chute of the settling furnace.

[0023] On the other hand, the present invention also provides a processing apparatus for high-conductivity aluminum busbars, the apparatus comprising:

[0024] The aluminum melting furnace, the first aluminum molten chute, the settling furnace, the second aluminum molten chute, the online degassing mechanism, the online filtration mechanism, the third aluminum molten chute, the casting box, the chain conveyor, and the sawing machine are arranged in sequence.

[0025] The outlet of the casting box corresponds to the central channel of the crystallizer, the outer edge of the crystallizer is connected to the cooling water pipe, and multiple water outlet holes are evenly distributed around the periphery of the central channel.

[0026] Optionally, the upper side wall of the casting box is provided with a flow channel, which corresponds to the third aluminum liquid chute.

[0027] Optionally, it also includes an emergency discharge port, which and the discharge port are located on opposite side walls of the casting box, and the emergency discharge port is detachably connected to the plug body.

[0028] Optionally, it also includes multiple clamping plates and multiple bolts. The clamping plates are provided with waist holes. One end of each of the multiple bolts is respectively connected to the side wall of the casting box around the discharge port. The other end of each bolt passes through one of the waist holes and is connected to a nut, so as to make the clamping plate, the crystallizer and the side wall of the casting box fit together in sequence.

[0029] Optionally, it also includes a box cover, wherein the casting box has an upper opening, the box cover is closed to the upper opening, and the box cover has a gas pipe mounting hole, a heater mounting hole, a level gauge mounting hole and a thermocouple mounting hole.

[0030] Compared to existing aluminum busbars, the aluminum busbars produced by this processing method have the following advantages:

[0031] (1) Significantly improved conductivity: The conductivity of aluminum busbar material can reach more than 62.5% IACS, which is 5 percentage points higher than that of conventional pure aluminum busbar (59.5% IACS). The overall voltage drop of the electrolytic cell busbar system is reduced, and the power consumption per ton of aluminum can be reduced by more than 30kWh.

[0032] (2) Good strength and toughness: The material has not been annealed, with a tensile strength ≥75 MPa and an elongation after fracture ≥30%, which meets the requirements of electrolytic cell busbar for mechanical strength and toughness.

[0033] (3) Significant comprehensive economic benefits: Taking the series with an annual output of 1.4 million tons of electrolytic aluminum as an example, it can save 42 million kWh of electricity every year.

[0034] (4) Existing aluminum busbars require hot rolling, annealing, and iron precipitation heat treatment. This preparation method uses AL99.7% + cold material in aluminum melting furnace + boronizing treatment in aluminum melting furnace + refining in aluminum melting furnace + refining in static furnace + online addition of aluminum-titanium-boron wire to refine grains + online degassing and filtration + direct casting without hot rolling to prepare a high conductivity aluminum busbar with ≥62.5% IACS. The production process is shorter, the cost is lower, and it is more compatible with electrolytic cells.

[0035] (5) The raw material is industrial aluminum with a purity of 99.7%, and the raw material cost is low because the slag is removed step by step.

[0036] (6) This method adopts a short-process casting of high-conductivity aluminum busbars without hot rolling or heat treatment. Traditional methods use hot rolling + annealing homogenization or hot rolling + iron precipitation heat treatment; this method directly casts after aluminum liquid purification, shortening the process, reducing energy consumption, and significantly reducing costs. This method also adds aluminum-titanium-boron wire online to refine the grains, making the microstructure more uniform and improving strength and toughness without reducing conductivity.

[0037] (7) The process is simple and easy to control, suitable for local large-scale production of electrolytic aluminum enterprises. The core processes are concentrated in smelting and purification + grain refinement + online treatment + direct casting, without the need for hot rolling line and heat treatment furnace; the parameters are easy to control, suitable for continuous production of electrolytic aluminum on site, energy saving and carbon reduction, and outstanding benefits.

[0038] (8) Deep removal of harmful elements such as vanadium and titanium significantly improves conductivity (boration and impurity removal stage). Boration treatment specifically combines vanadium and titanium to form stable boride precipitates, and then combined with multiple rounds of refining and slag removal, to achieve deep removal of vanadium and titanium.

[0039] Multiple rounds of slag removal are superimposed: boride precipitates, primary oxide slag, and foreign inclusions are removed layer by layer, and the purity of the aluminum melt reaches a high level.

[0040] Advantages: Significantly reduces the negative impact of trace impurities on conductivity, which is a key guarantee for high conductivity aluminum busbar blanks.

[0041] (9) Extreme control of hydrogen and inclusions, with defects almost eliminated;

[0042] The entire process includes multiple argon + refining agent slag removal and degassing processes, combined with preliminary physical homogenization and stirring;

[0043] Multiple refining processes: coarse slag, fine suspended inclusions, and micron-sized impurities are removed step by step;

[0044] Repeated dehydrogenation reduces the hydrogen content to a low level, essentially eliminating casting defects such as pinholes, porosity, looseness, inclusions, and black spots.

[0045] Continuous degassing through multiple processes: effectively suppresses secondary hydrogen absorption and ensures product quality.

[0046] (10) Two-stage grain refinement, uniform grain structure and comprehensive performance improvement

[0047] First stage: Physical homogenization and refinement, relying on mechanical stirring to break up the initial coarse grains and dendrites, laying the foundation for a uniform structure;

[0048] Second stage: Chemical refinement of aluminum-titanium-boron wire introduces a large number of heterogeneous nucleation cores to further refine the grains and inhibit grain growth;

[0049] Effects: The cast billet has fine and uniform grains, which significantly improves its mechanical properties (strength, elongation, toughness, and fatigue resistance); at the same time, the uniform grains improve the processing performance of aluminum, making it less prone to cracking during rolling, extrusion, and bending, and resulting in better surface quality.

[0050] (11) High process tolerance and highly stable batch quality

[0051] Multiple refining, impurity removal, and detailed processing steps ensure thorough quality control.

[0052] Fluctuations in a single process (such as stirring time, refining agent dosage, and residence time) are compensated for by subsequent processes;

[0053] The composition, impurities, gases, and grain state are highly consistent across batches, making it suitable for continuous mass production and significantly improving the finished product qualification rate and yield. Conventional single-stage processes are greatly affected by the melting and refining time, resulting in significant batch-to-batch fluctuations in indicators and inconsistent product performance.

[0054] (12) Better thermal stability and operational reliability (long-term service advantage)

[0055] Low impurities and fine grain structure improve resistance to thermal fatigue and thermal expansion and contraction. During long-term operation of the busbar, it is less prone to grain growth, grain boundary embrittlement and cracking.

[0056] With fewer impurities and more uniform conductivity, the phenomenon of local overheating and hot spots on the busbar is greatly reduced, thus lowering the risk of arcing, ablation, and short circuits, and extending the equipment operation and maintenance cycle.

[0057] (13) Better compatibility with subsequent processing and installation

[0058] With uniform grains and excellent plasticity, the busbar is not prone to cracking or burrs during cutting, welding and processing, resulting in a high yield of finished products.

[0059] The surface is clean and dense, the welding fusion is good, the weld is free of porosity and slag inclusions, and the conductivity of the joint is close to that of the base material, so there will be no problems such as excessive joint resistance or severe overheating.

[0060] (14) According to the current national standard, the cross-sectional dimensions of copper, aluminum and their alloy busbars for electrical use (GB / T5585.2-2018) are: 2.24 mm ≤ thickness ≤ 31.5 mm; 16.00 mm ≤ width ≤ 200.00 mm. However, at present, the busbar system of aluminum electrolytic cells is generally designed to be made of large-size cast aluminum flat ingots in order to meet the requirements of high current carrying capacity. The cross-sectional dimensions are: 50.00 mm ≤ thickness ≤ 250 mm, 100.00 mm ≤ width ≤ 750.00 mm, which far exceeds the national standard range. Attached Figure Description

[0061] Figure 1 A schematic diagram of a production apparatus provided in an embodiment of the present invention;

[0062] Figure 2 This is a three-dimensional view of the casting box;

[0063] Figure 3 This is a top view of the casting box;

[0064] Figure 4 for Figure 2 Enlarged view of section A;

[0065] Figure 5 for Figure 3 Enlarged view of section B.

[0066] The reference numerals in the accompanying drawings include: 1. Aluminum melting furnace; 2. First aluminum melt chute; 3. Settling furnace; 4. Online degassing mechanism; 5. Online filtration mechanism; 6. Third aluminum melt chute; 7. Casting box; 8. Chain conveyor; 9. Sawing machine; 10. Cooling water pipe; 11. Crystallizer; 12. Drainage channel; 13. Emergency discharge port; 14. Plug; 15. First connecting rod; 16. Second connecting rod; 17. Limiting screw; 18. Handwheel; 19. Notch; 20. Pressure plate; 21. Bolt; 22. Box cover; 23. Upper opening; 24. Gas pipe mounting hole; 25. Heater mounting hole; 26. Liquid level gauge mounting hole; 27. Thermocouple mounting hole; 28. Water outlet; 29. ​​Material outlet. Detailed Implementation

[0067] To further illustrate the technical means and effects adopted by the present invention to achieve the intended purpose, the specific embodiments, structures, features, and effects according to the present invention will be described in detail below with reference to the accompanying drawings and preferred embodiments. In the following description, different "embodiments" or "embodiments" do not necessarily refer to the same embodiment. Furthermore, specific features, structures, or characteristics in one or more embodiments can be combined in any suitable form.

[0068] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0069] On one hand, one embodiment of the present invention provides a high-conductivity aluminum busbar, wherein the aluminum busbar contains the following elements by mass percentage: Fe≤0.10%; Si≤0.06%; Cu≤0.001%; ​​Mn≤0.001%; ​​Mg≤0.001%; ​​Zn≤0.005%; Ni≤0.005%; Cr≤0.003%; Ti+V≤0.004%; B≤0.005%; other impurity elements≤0.1%; Al≥99.75%.

[0070] Specifically, the Fe / Si ratio is controlled as follows: Fe content ≤ 0.10%, Si content ≤ 0.06%, Fe / Si ratio 1.13-1.71, core ratio controlled at 1.3-1.4, to ensure the formation of α-AlFeSi phase and avoid the formation of needle-like β phase. The α phase is skeletal and has little effect on electron scattering, which is beneficial to improving conductivity.

[0071] Ti+V Limit Control: Ti and V are the most detrimental impurity elements to the conductivity of aluminum. Their solid solution state has a strong scattering effect on electrons. Controlling the total amount of Ti+V below 0.004% is the key to ensuring that the DC resistivity (Ωmm2 / m) of the aluminum busbar is ≤0.02795 and the conductivity is >62.5% IACS.

[0072] The production line, in order of material flow, includes: an aluminum melting furnace, a settling furnace, a powder spraying refining machine, an automatic wire feeder, an online degassing mechanism, a plate filter mechanism, a casting box, a cooling device, a chain conveyor, and a cutting device. The devices are connected by a conveying mechanism to form a continuous production line.

[0073] The production process flow of high conductivity aluminum busbars is shown in the figure:

[0074] Aluminum melting furnace (refining + degassing) ─▶ Holding furnace (refining + degassing) ───▶ Enclosed chute automatic wire feeder ───▶ Online degassing ───▶ Plate filter ───▶ Casting box ───▶ Cooling device (crystallizer) ───▶ Chain conveyor ───▶ Sawing machine ───▶ Surface finishing ───▶ Finished product inspection

[0075] On the other hand, another embodiment of the present invention also provides a method for processing a high-conductivity aluminum busbar, the method comprising the following steps:

[0076] S1 Furnace Loading: Electrolytic aluminum liquid and solid aluminum ingots are used as raw materials and fed into the aluminum melting furnace and stirred. 200-300 kg of solid aluminum ingot cold material is mixed in with each ton of electrolytic aluminum liquid. The solid aluminum ingots are pre-added in a fixed quantity. The purity of both the electrolytic aluminum liquid and the solid aluminum ingots is 99.70%.

[0077] Adding solid aluminum ingot cold material can quickly and accurately control the temperature of the molten aluminum to 730-750℃, improve production cycle and heat exchange efficiency, and reduce secondary oxidation; at the same time, it generates sufficient supercooling to promote nucleation; combined with stirring, it increases the number of crystal nuclei; and it uses physical mechanisms to initially refine the grains.

[0078] S2 Initial Refining: Adjust the temperature of the molten aluminum in the melting furnace to 730-750℃ and carry out powder refining. Use a spray gun to inject argon gas and granular fluorine-free environmentally friendly refining agent into the molten aluminum. This has the dual effect of gas stirring and flux refining, which can effectively remove hydrogen and non-metallic inclusions in the molten aluminum. Then remove the scum on the surface of the molten aluminum to ensure the purity of the molten aluminum. The initial refining time is 15 minutes.

[0079] S3 Boring Treatment: Al-4B aluminum-boron alloy is strategically added to the lower part of the molten aluminum, mechanically stirred, and bottom-blown with argon gas to further agitate the molten aluminum. This allows the Al-4B alloy to melt rapidly, and boron atoms to diffuse uniformly into the molten aluminum, where they undergo directional reactions with Ti and V (ALB4 + 2Ti → 2TiB2↓ + Al; AlB4 + 2V → 2VB2↓ + Al), generating TiB2 / VB2 (high-melting-point boride) solid particles. After standing for 20-30 minutes, a large amount of boride solid particles settle to the bottom of the furnace (periodically removed). After boring treatment, the concentration of Ti + V in the molten aluminum is controlled to be ≤0.004%, and B ≤0.005%. If these standards are not met, 0.02%-0.05% Al-4B alloy is added, and the above reaction and separation steps are repeated. The aim is to improve electrical conductivity.

[0080] S4 Tilting: Pour the molten aluminum from the aluminum melting furnace into a settling furnace, leaving molten aluminum in the aluminum melting furnace at 10% of its total capacity;

[0081] S5 Refining: The temperature of the molten aluminum in the settling furnace is adjusted to 720-740℃ for powder refining. Argon gas and granular fluorine-free environmentally friendly refining agent are injected into the molten aluminum using a spray gun. This has the dual effects of gas stirring and flux refining, which can effectively remove hydrogen and non-metallic inclusions from the molten aluminum and remove the slag on the surface of the molten aluminum. The refining time is 15 minutes. After refining, the hydrogen content of the molten aluminum is reduced to ≤0.12mL / 100gAl, and the cleanliness of the melt reaches the Class A standard, taking into account both purification effect and green production requirements.

[0082] When the temperature of the molten aluminum at the outlet of the settling furnace is controlled to 710-720℃, aluminum-titanium-boron wire (AL5Ti1B) is added at the outlet chute of the settling furnace. An automatic wire feeding device (with speed adjustment function, the wire feeding speed is precise and controllable) is used. According to different product specifications, the amount of aluminum-titanium-boron wire added and the wire feeding speed can be automatically set to solve the problems of uneven grain refinement and grain growth, so as to make the nucleation of aluminum melt grains uniform.

[0083] The S6 online degassing and plate filtration system features a double-layer insulation and electric heating design for the online degassing mechanism. From degassing to filtration, the temperature drop of the molten aluminum is ≤5℃, preventing temperature fluctuations from affecting melt flowability and purification efficiency. The online degassing mechanism employs a rotor-type microbubble dispersion process, using argon gas for treatment, with continuous argon protection. The rotor speed is controlled at 450-500 rpm. This eliminates secondary hydrogen absorption and oxidation, while reducing the load on the subsequent plate filtration system. The plate filtration mechanism also features a double-layer insulation and electric heating design, ensuring a temperature drop of ≤5℃ from degassing to filtration, again preventing temperature fluctuations from affecting melt flowability and purification efficiency. The plate filtration system uses 50-mesh ceramic filter plates for high-precision filtration of the degassed melt, removing fine inclusions and ensuring melt purity, providing slag-free melt for high-conductivity aluminum busbar ingot casting.

[0084] Specifically, the molten aluminum at the outlet of the settling furnace contains a certain amount of hydrogen and other residues (alkali metals, inclusions), which are removed after being treated by the degassing equipment.

[0085] The degassing equipment operates on the principle of gas flotation. The process gas (inert gas or a mixture of inert gas and chlorine) is injected into the melt via a rotor and broken into uniformly dispersed microbubbles. These microbubbles rise to the surface of the melt, completing the following tasks during their ascent:

[0086] Hydrogen is adsorbed into the bubbles and then expelled;

[0087] Alkali metals are eliminated by reacting chemically with chlorine gas (forming chlorides);

[0088] The impurities are captured by bubbles, then rise to the surface of the melt to form slag, and are finally filtered out by a 50-mesh ceramic filter plate.

[0089] S7 Casting: In the casting process, aluminum ingot blanks are cast using a horizontal casting method. The casting temperature is 680-720℃, the casting speed is 120-400mm / min, the cooling water pressure is 0.25-0.35MPa, and the cooling water temperature is 15-25℃. Under the above control conditions, stable continuous casting is achieved. The crystallizer is made of copper, which has high hardness, good wear resistance, and high thermal conductivity. It can instantly remove the heat from the aluminum liquid, achieving strong primary cooling. The cast aluminum blanks have a smooth surface, which can reduce subsequent processing.

[0090] Specifically, a description of the casting and subsequent processing equipment:

[0091] (1) The chain conveyor with speed control can adjust the drawing speed according to the ingot specifications:

[0092] Larger sizes use lower drawing speeds to ensure sufficient cooling; smaller sizes use higher drawing speeds to improve production efficiency.

[0093] (2) Surface treatment after sawing: The cut aluminum busbar is subjected to surface treatment, including:

[0094] Remove surface oxide scale; trim burrs; perform surface processing to achieve the surface roughness required by the design.

[0095] Specifically, the crystallizer is located at the outlet of the casting box. The crystallizer has a frame-shaped structure. The outer edge of the frame-shaped structure is connected to the cooling water inlet and outlet pipes. Multiple cooling holes are arranged sequentially on the inner edge of the frame-shaped structure. The diameter of the cooling holes is <3.0mm and the spacing between the holes is <6mm.

[0096] The copper crystallizer has a high thermal conductivity (about 390 W / m·K), which is much higher than that of the traditional cast iron crystallizer (about 60 W / m·K). The technical effects are: (1) rapid solidification and grain refinement; (2) reduced segregation and improved microstructure uniformity; (3) avoidance of central cracks and surface quality defects.

[0097] The beneficial effects of this processing method are summarized again as follows:

[0098] (1) Raw material optimization: Based on 99.7% AL aluminum liquid, a micro-alloying design is carried out. The core is to control the content of impurity elements in the melt. Boring treatment technology is used to remove elements such as V and Ti that are prone to electron scattering in the aluminum liquid. The reactants are removed after settling to the bottom. A fluorine-free particulate environmentally friendly refining agent + argon refining is used to efficiently remove hydrogen and slag. The aluminum melting furnace and the holding furnace are used for dual refining process to efficiently purify the melt.

[0099] (2) Grain refinement technology: The grains are initially refined by quantitative addition of solid cold material using physical mechanisms; the online aluminum-titanium-boron wire addition process is used to precisely add and refine the melt grains;

[0100] (3) Aluminum liquid purification process: The online degassing + plate filter series purification process is adopted. High-purity argon is used as the degassing medium. The aluminum liquid is further purified through functions such as uniform stirring, degassing, heat preservation and filtration, so as to provide high-quality billets for subsequent casting.

[0101] like Figure 1 , Figure 2 As shown, another embodiment of the present invention also provides a processing apparatus for high conductivity aluminum busbars, the apparatus comprising: an aluminum melting furnace 1, a first aluminum liquid chute 2, a settling furnace 3, a second aluminum liquid chute, an online degassing mechanism 4, an online filtration mechanism 5, a third aluminum liquid chute 6, a casting box 7, a chain conveyor 8, and a sawing machine 9 arranged in sequence.

[0102] The discharge port 29 of the casting box 7 corresponds to the central channel of the crystallizer 11. The outer edge of the crystallizer 11 is connected to the cooling water pipe 10. Multiple water outlets 28 are evenly distributed around the periphery of the central channel.

[0103] Specifically, the crystallizer 11 is made of copper, which has high strength, good heat dissipation, and fast cooling, thus improving production efficiency and producing products with good surface quality.

[0104] Specifically, the drive motor of the chain conveyor 8 is equipped with a speed-regulating frequency converter, which facilitates the control of the pulling speed of the aluminum busbar, thereby matching the feeding speed of the aluminum liquid in the casting box 7, and thus stabilizing the liquid level of the aluminum liquid in the casting box 7.

[0105] Specifically, a scale is installed on the side of the chain conveyor 8 to measure the length and straightness of the aluminum busbar.

[0106] Specifically, temperature sensors are installed in the aluminum melting furnace 1, the settling furnace 3, the online degassing mechanism 4, and the online filtration mechanism 5.

[0107] like Figure 4 As shown, specifically, the crystallizer 11 is rectangular in shape, and the solid part of the crystallizer 11 has a hollow cavity. The cooling water pipe 10 includes cooling water pipe 10A, cooling water pipe 10B, cooling water pipe 10C, and cooling water pipe 10D. One end of cooling water pipe 10A, cooling water pipe 10B, cooling water pipe 10C, and cooling water pipe 10D are respectively connected to the left and right sides of the crystallizer 11, and the other end of cooling water pipe 10A, cooling water pipe 10B, cooling water pipe 10C, and cooling water pipe 10D are respectively connected to a water distributor. The water distributor is equipped with a temperature sensor and a pressure sensor.

[0108] like Figure 3 As shown, in a specific embodiment, the upper side wall of the casting box 7 is provided with a flow channel 12, which corresponds to the third aluminum liquid chute 6.

[0109] In this embodiment, specifically, one end of the third aluminum liquid chute 6 is connected to the online filtration mechanism 5, and the other end is connected to the diversion trough 12, which is used to divert the degassed and filtered aluminum liquid into the casting box 7.

[0110] like Figure 5 As shown, in a specific embodiment, an emergency discharge port 13 is also included. The emergency discharge port 13 and the discharge port 29 are located on opposite side walls of the casting box 7, and the emergency discharge port 13 is detachably connected to the plug body 14.

[0111] In this embodiment, specifically, during the normal operation of the processing device, the emergency discharge port 13 is blocked by the plug 14, and the molten aluminum in the casting box 7 can only flow out through the discharge port 29 to complete the subsequent casting and cutting of the aluminum busbar.

[0112] In the event of an emergency and the suspension of aluminum busbar production, the operator can pull out the plug 14 in the emergency discharge port 13 to facilitate the discharge of molten aluminum from the casting box 7 to the slag box, thus preventing the molten aluminum from cooling and solidifying in the casting box 7.

[0113] Specifically, the plug body 14 is made of carbon steel inner core and aluminum silicate fiber plug cap that wraps the carbon steel inner core. The outer diameter of the emergency discharge port 13 is larger than its inner diameter, and the shape of the plug body 14 matches the shape of the emergency discharge port 13.

[0114] Specifically, it also includes a pushing mechanism for pressing the plug 14 against the emergency discharge port 13. The pushing mechanism includes a first connecting rod 15, a second connecting rod 16, a limiting screw 17, and a handwheel 18. One end of the first connecting rod 15 is hinged to the side wall of the casting box 7 on one side of the emergency discharge port 13, and the other end is provided with a notch 19. One end of the second connecting rod 16 is hinged to the middle of the first connecting rod 15, and the other end of the second connecting rod 16 is fixedly connected to the plug 14. One end of the limiting screw 17 is hinged to the side wall of the casting box 7 on the other side of the emergency discharge port 13, and the limiting screw 17 corresponds to the notch 19. The other end of the limiting screw 17 is threaded to the handwheel 18, which is used to drive the first connecting rod 15 to rotate towards the emergency discharge port 13, thereby pushing the plug 14 into the emergency discharge port 13.

[0115] When it is necessary to urgently discharge molten aluminum, disassemble the handwheel 18 to disengage it from the first connecting rod 15, and rotate the limit screw 17 upward to disengage it from the notch 19. Then, rotate the first connecting rod 15 away from the emergency discharge port 13 to drive the plug 14 away from the emergency discharge port 13.

[0116] In a specific embodiment, it also includes multiple clamping plates 20 and multiple bolts 21. The clamping plates 20 are provided with waist holes. One end of each of the multiple bolts 21 is respectively connected to the side wall of the casting box 7 around the discharge port 29. The other end of each bolt 21 passes through one of the waist holes and is connected to a nut, so as to make the clamping plates 20, the crystallizer 11 and the side wall of the casting box 7 fit together in sequence.

[0117] In this embodiment, specifically, changing the position of the bolt 21 in the waist hole can change the contact position and contact area between the clamping plate 20 and the crystallizer 11, thereby adjusting the clamping force received by the crystallizer 11, thus ensuring the stability of the crystallizer 11, and ensuring the stability of the cooling water flow contacted by the aluminum busbar around the surface of the aluminum busbar when the aluminum busbar passes through the central channel of the crystallizer 11.

[0118] In a specific embodiment, it also includes a box cover 22. The casting box 7 has an upper opening 23, and the box cover 22 covers the upper opening 23. The box cover 22 has a gas pipe mounting hole 24, a heater mounting hole 25, a level gauge mounting hole 26, and a thermocouple mounting hole 27.

[0119] In this embodiment, specifically, the box cover 22 is used first to seal the aluminum liquid inside the casting box 7 from the air;

[0120] Argon gas is introduced into the casting box 7 through a gas pipe as a protective gas to isolate air and inhibit hydrogen intrusion, thus ensuring the quality of the molten aluminum and the finished product.

[0121] By installing a U-shaped silicon dioxide electric heater in the heater mounting hole 25 and a temperature sensor in the thermocouple mounting hole 27, fully automatic closed-loop control of the aluminum liquid temperature in the casting box 7 can be achieved, and the temperature can be automatically adjusted according to the casting product.

[0122] A laser level gauge is installed in the level mounting hole to monitor the level of the casting box 7 in real time. The data is uploaded to the central control room. By adjusting the size of the outlet of the static furnace 3, the level of the casting box 7 is automatically adjusted.

[0123] By installing the aforementioned liquid level and temperature control components, this device achieves full-domain automated control via PLC: the system is centrally managed by the PLC, significantly improving the level of automation and product qualification rate.

[0124] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A high-conductivity aluminum busbar, characterized in that, The aluminum busbar contains the following elements by mass percentage: Fe≤0.10%; Si≤0.06%; Cu≤0.001%; ​​Mn≤0.001%; ​​Mg≤0.001%; ​​Zn≤0.005%; Ni≤0.005%; Cr≤0.003%; Ti+V≤0.004%; B≤0.005%; other impurity elements≤0.1%; Al≥99.75%.

2. A method for processing a high-conductivity aluminum busbar, characterized in that, Includes the following steps: S1 Furnace Loading: Electrolytic aluminum liquid and solid aluminum ingots are used as raw materials and fed into the aluminum melting furnace and stirred. 200-300 kg of solid aluminum ingot cold material is mixed in with each ton of electrolytic aluminum liquid. The solid aluminum ingots are pre-added in a fixed quantity. The purity of both the electrolytic aluminum liquid and the solid aluminum ingots is 99.70%. S2 initial refining: Adjust the temperature of the aluminum liquid in the aluminum melting furnace to 730-750℃, carry out powder refining, use a spray gun to inject argon gas and refining agent into the aluminum liquid, and remove the slag on the surface of the aluminum liquid. S3 boronizing treatment: The aluminum-boron alloy Al-4B is added to the aluminum liquid, mechanically stirred, and argon gas is used for bottom blowing and coordinated stirring. After standing, the borate at the bottom of the aluminum melting furnace is removed. S4 furnace turning: Pour the molten aluminum in the aluminum melting furnace into a holding furnace, leaving a certain amount of molten aluminum in the aluminum melting furnace; S5 Refining: Adjust the temperature of the aluminum liquid in the static furnace to 720-740℃, carry out powder refining, use a spray gun to inject argon and refining agent into the aluminum liquid, and remove the slag on the surface of the aluminum liquid. S6 online degassing and filtration; S7 casting.

3. The processing method for the high conductivity aluminum busbar according to claim 2, characterized in that, The initial refining time and the subsequent refining time are both 15 minutes; During the boronizing process, the aluminum liquid should be left to stand for 20-30 minutes. When the furnace is turned over, the amount of molten aluminum retained in the aluminum melting furnace is 10% of the total capacity of the aluminum melting furnace; During the casting process, the casting temperature is 680-720℃, the casting speed is 120-400mm / min, the cooling water pressure is 0.25-0.35MPa, and the cooling water temperature is 15-25℃.

4. The processing method for high-conductivity aluminum busbar according to claim 2, characterized in that, During the online degassing and filtration process, the aluminum liquid temperature is reduced by ≤5℃ throughout the process. First, a rotor-type microbubble dispersion process is used to achieve degassing, and then a 50-mesh ceramic filter plate is used to filter the aluminum liquid.

5. The processing method for the high conductivity aluminum busbar according to claim 2, characterized in that, After refining, the molten aluminum flows out of the settling furnace. After adjusting the temperature of the molten aluminum to 710-720℃, aluminum-titanium-boron wire is added at the outlet chute of the settling furnace.

6. A processing apparatus for high-conductivity aluminum busbars, characterized in that, include: The aluminum melting furnace, the first aluminum molten chute, the settling furnace, the second aluminum molten chute, the online degassing mechanism, the online filtration mechanism, the third aluminum molten chute, the casting box, the chain conveyor, and the sawing machine are arranged in sequence. The outlet of the casting box corresponds to the central channel of the crystallizer, the outer edge of the crystallizer is connected to the cooling water pipe, and multiple water outlet holes are evenly distributed around the periphery of the central channel.

7. The processing apparatus for high-conductivity aluminum busbars according to claim 6, characterized in that, The upper side wall of the casting box is provided with a flow channel, which corresponds to the third aluminum liquid chute.

8. The processing apparatus for high-conductivity aluminum busbars according to claim 6, characterized in that, It also includes an emergency discharge port, which and the discharge port are located on opposite side walls of the casting box, and the emergency discharge port is detachably connected to the plug body.

9. The processing apparatus for high-conductivity aluminum busbars according to claim 6, characterized in that, It also includes multiple clamping plates and multiple bolts. The clamping plates are provided with waist holes. One end of each of the multiple bolts is respectively connected to the side wall of the casting box around the discharge port. The other end of each bolt passes through one of the waist holes and is connected to a nut, so as to make the clamping plates, the crystallizer and the side wall of the casting box fit together in sequence.

10. The processing apparatus for high-conductivity aluminum busbars according to claim 6, characterized in that, It also includes a box cover, the casting box having an upper opening, the box cover being closed to the upper opening, and the box cover having a gas pipe mounting hole, a heater mounting hole, a level gauge mounting hole and a thermocouple mounting hole.

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