Device for preparing composite hammerhead of medium-large hammer crusher through medium-frequency induction heating

Abstract

The utility model discloses a device for preparing a composite hammerhead of a medium-large hammer crusher by medium-frequency induction heating, which is characterized in that a cylindrical sand box is arranged on a movable flatcar, and a first space for accommodating a hammerhead model is arranged in the cylindrical sand box; the movable flatcar is arranged on a cement foundation in a sliding mode, and the cylindrical sand box is arranged on the movable flatcar and can be driven by the movable flatcar to move back and forth. The ground fixing support is fixedly arranged on the side edge of the movable flatcar. The lifting mechanism is arranged on the top of the ground fixing support. A coil bracket of the medium-frequency induction heater is a cylinder with upper and lower openings; the heating coil is insulated from the coil support and is arranged in the coil support in a surrounding manner along the side wall of the coil support, and a second space for accommodating the cylindrical sand box is formed in the middle of the surrounding heating coil; the supporting platform is horizontally arranged on the side, away from the movable flatcar, of the coil support, the balance weight is arranged at the end, away from the coil support, of the supporting platform, and the medium-frequency induction heater can move up and down under driving of the lifting mechanism.

Description

Technical Field

[0001] This utility model relates to the field of casting technology, and in particular to a device for preparing composite hammers for medium and large hammer crushers using medium-frequency induction heating. Background Technology

[0002] As a key crushing equipment in mining, construction, cement, metallurgy, and waste recycling, the performance of the hammer, its core component, directly determines the equipment's working efficiency and service life. With the increasing demands from industry for material crushing efficiency, equipment durability, and resource recycling, traditional single-material hammers are no longer sufficient to meet the requirements of high-intensity, high-wear conditions. The introduction of composite hammer technology provides an important direction for resolving this contradiction. However, in the manufacturing of hammers for medium and large-sized hammer crushers, the technological bottleneck of composite processes has not yet been overcome, resulting in a continued reliance on single high-manganese steel materials, which severely restricts further improvements in equipment performance.

[0003] Traditional hammerhead materials are primarily high-manganese steel, which can form a surface hardened layer under impact loads through its work-hardening properties. However, when crushing high-hardness, high-impact materials such as construction waste and scrapped cars, high-manganese steel hammerheads suffer from insufficient wear resistance and short lifespan. To balance wear resistance and toughness, composite hammerhead technology has emerged. This technology combines high-hardness materials (such as high-chromium cast iron and cemented carbide) with high-toughness matrix materials (such as alloy steel) to form a "rigid-flexible" structure. Currently, mainstream composite technologies include: inlay composite, which involves embedding cemented carbide or ceramic preforms into the working surface of the hammerhead, but this suffers from low bonding strength and easy detachment; and bimetallic composite casting, which is divided into liquid-liquid composite (simultaneous pouring of two molten metals) and solid-liquid composite (pre-casting the hammer handle and then pouring the hammerhead material). Among these, solid-liquid composite has become the mainstream solution for small and medium-sized composite hammerheads due to its relatively controllable process. Composite hammerheads perform well when crushing medium-hardness materials such as coal and limestone, increasing their lifespan by 2 to 3 times, but their application is still limited to small and medium-sized equipment. However, there are still technical bottlenecks in casting medium and large composite hammerheads. Hammerheads for medium and large hammer crushers (such as those used for crushing construction waste and scrap cars) need to withstand higher impact loads and complex wear, which places stringent requirements on the composite process. For example, there is a contradiction between structural strength and composite process. The hammer handle of medium and large hammerheads needs to have high bending and fatigue resistance, resulting in its width and thickness being close to that of the hammerhead (for example, the width of the hammer handle is more than 80% of the hammerhead). However, traditional solid-liquid composite processes rely on the molten liquid to fully encapsulate the slender hammer handle to achieve metallurgical bonding, while the thick structure of medium and large hammer handles makes the molten liquid... The liquid can only cover the surface, resulting in insufficient effective bonding area and defects such as incomplete fusion and porosity at the interface. There is also the problem of mismatch between thermal stress and material properties. The solidification shrinkage rates of high-chromium cast iron (hammer head material) and alloy steel (hammer handle material) differ significantly, generating huge residual stress on the thick interface, leading to cracking of the composite layer or even overall fracture. There are also challenges in process control. Liquid-liquid composite requires precise control of the pouring temperature and timing of the two molten metals, resulting in a narrow process window. Solid-liquid composite has extremely high requirements for the positioning accuracy and wettability of the prefabricated hammer handle, and existing technologies are difficult to meet the needs of large-scale production of medium and large hammer heads.

[0004] Currently, medium and large hammerheads are still mainly made of high-manganese steel. Although performance can be improved by surface hard alloy welding or local embedding of wear-resistant blocks, there are many problems. Hard alloy welding is inefficient, has a large heat-affected zone, easily leads to degradation of the base material properties, and has insufficient bonding strength. Embedded composites can only locally enhance wear resistance and cannot solve the problems of overall structural strength and impact resistance. Bimetallic composite casting is limited by the maturity of the process, and the quality of the composite interface is unstable, making it difficult to eliminate internal stress through conventional heat treatment. There is an urgent need to develop a device that can reliably bond high-hardness materials and tough base materials while ensuring the structural strength of the hammer handle, while reducing interfacial stress and improving process stability.

[0005] The above background information is provided only to aid in understanding the concept and technical solution of this utility model. It does not necessarily belong to the prior art of this patent application. In the absence of clear evidence that the above information was disclosed on the filing date of this patent application, the above background information should not be used to evaluate the novelty and inventiveness of this application. Utility Model Content

[0006] The purpose of this invention is to provide a device for preparing composite hammerheads for medium and large hammer crushers using medium-frequency induction heating, so as to solve the technical problems of immature process and unstable composite interface quality in the existing technology.

[0007] Therefore, this utility model proposes a device for preparing composite hammerheads for medium and large hammer crushers using medium-frequency induction heating.

[0008] Preferably, the present invention has the following technical features:

[0009] An apparatus for preparing composite hammerheads for medium-to-large hammer crushers using medium-frequency induction heating includes a cylindrical sand box, a mobile flatcar, a ground-fixed support, a lifting mechanism, and a medium-frequency induction heater. The cylindrical sand box is mounted on the mobile flatcar, and its interior has a first space for accommodating hammerhead models. The mobile flatcar is slidably mounted on a concrete foundation. Driven by the mobile flatcar, the cylindrical sand box can move back and forth to enter or exit the medium-frequency induction heater. The ground-fixed support is fixedly mounted on the side of the mobile flatcar. The lifting mechanism... The intermediate frequency induction heater is located on top of the ground-fixed support. It includes a coil support, a heating coil, and a support platform. The coil support is a cylindrical shape with openings at the top and bottom. The heating coil is insulated from the coil support and is arranged around the side wall of the coil support. There is a second space in the middle of the coil to accommodate the cylindrical sand box. The support platform is horizontally arranged on the side of the coil support away from the moving flatcar. A counterweight is provided at the end of the support platform away from the coil support. The intermediate frequency induction heater can move up and down under the drive of the lifting mechanism.

[0010] Preferably, the cylindrical sand box is made of stainless steel plate by welding, and has an opening at the top.

[0011] Preferably, a number of lifting lugs are provided on the upper end and sides of the cylindrical sand box.

[0012] Preferably, a first chute is provided on the cement foundation, and several guide rails are provided on the bottom surface of the first chute. The moving flatcar is set on the guide rails so that the cylindrical sand box can move back and forth in the first chute.

[0013] Preferably, the ground-fixed support includes a horizontal frame, two vertical frames, and a lifting platform. The horizontal frame is disposed adjacent to the cement foundation; the lifting platform is disposed directly above the horizontal frame; and the two vertical frames are disposed between the lifting platform and the horizontal frame.

[0014] Preferably, the vertical frame is a right-angled trapezoid shape, including a vertical beam, an inclined beam and a top beam. The vertical beam is a smooth cylinder. Guide sliders are provided on the front and rear sides of the support platform. The guide sliders are vertically provided with a second sliding groove that matches the vertical beam. Driven by the lifting mechanism, the medium-frequency induction heater can move up and down along the vertical beam.

[0015] Preferably, an optical axis hole is provided on the support platform near the counterweight, and a guide optical axis is vertically arranged through the optical axis hole. Its upper end and lower end are respectively fixed to the lifting platform and the horizontal frame. The center of the guide optical axis and the center of the guide slider are triangularly distributed.

[0016] Preferably, the lifting mechanism includes a winch, a pulley, a wire rope, and a controller. The winch and the pulley are fixedly mounted side by side on the top of the ground-fixed support via a first bracket and a second bracket, respectively. The beginning of the wire rope is fixed on the drum of the winch, passes through the pulley, and the end is fixed on the support platform near the medium-frequency induction heater. The lifting mechanism is controlled by the controller.

[0017] Preferably, the wire rope at the winch passes through the wire hole, and the distance from the center line of the wire rope at the wire hole to the center line of the coil support of the medium frequency induction heater is the same as the distance from the center line of the counterweight to the center line of the wire rope at the wire hole.

[0018] Preferably, a first limiter and a second limiter can be provided at the upper and lower ends of the vertical beam, respectively, to control the lifting limit positions of the medium-frequency induction heater.

[0019] The beneficial effects of this utility model compared with the prior art include: The device involved in this utility model is used to prepare composite hammerheads for medium and large hammer crushers. The cylindrical sand box with the hammerhead model is moved to the bottom of the medium-frequency induction heater by a moving flatcar. Preheating can be performed before casting to reduce the sudden cooling stress when the hammer handle preform comes into contact with the liquid metal of the hammerhead, and to avoid the initiation of microcracks caused by the difference in thermal expansion coefficients. After casting, the medium-frequency induction heater can be restarted to induction heat the composite hammerhead again, eliminating shrinkage porosity and segregation. The high-frequency electromagnetic field drives the micro-flow of the molten metal, filling the micro-pores formed by solidification shrinkage, making the grains finer, improving the interface structure, making the bonding surface more stable, and resulting in superior performance and less likelihood of hammerhead breakage. Attached Figure Description

[0020] Figure 1 This is a first overall schematic diagram of a specific embodiment of the present invention (the medium-frequency induction heater is not fitted into the cylindrical sand box).

[0021] Figure 2 This is a second overall schematic diagram of a specific embodiment of the present invention (the cylindrical sand box is moved directly below the medium-frequency induction heater).

[0022] Figure 3 This is a third overall schematic diagram of a specific embodiment of the present invention (the medium-frequency induction heater is fitted into the cylindrical sand box).

[0023] Figure 4 This is a fourth overall schematic diagram of a specific embodiment of the present invention (a top view of the medium-frequency induction heater before it is fitted into the cylindrical sand box).

[0024] Figure 5 This is a partial schematic diagram of a specific embodiment of the present invention.

[0025] Figure 6 This is a schematic diagram (with counterweight) of the induction heater in a specific embodiment of this utility model.

[0026] Figure 7 This is a top view (with counterweight) of the induction heater in a specific embodiment of this utility model.

[0027] Figure 8 This is a schematic diagram (with hammer head model) of a cylindrical sand box according to a specific embodiment of this utility model.

[0028] Figure 9 This is a schematic diagram of a ground-fixed bracket according to a specific embodiment of this utility model.

[0029] Explanation of reference numerals in the attached drawings: 02-Hammer head model; 021-Riser; 03-Cylindrical sand box; 031-Lifting lug; 032-First space; 04-Medium frequency induction heater; 041-Heating coil; 042-Coil support; 043-Support platform; 431-Guide slider; 432-Second chute; 433-Optical shaft hole; 434-Wire hole; 044-Second space; 05-Cement foundation; 051-First chute; 06- Guide rail; 07-Moving flatcar; 08-Ground fixed support; 081-Horizontal frame; 811-Front beam; 812-Rear beam; 813-Left beam; 814-Right beam; 082-Vertical frame; 821-Vertical beam; 822-Diagonal beam; 823-Top beam; 083-Lifting platform; 09-Counterweight; 10-Guide optical shaft; 11-Winch; 12-Pulley; 13-Wire rope; 14-First support; 15-Second support. Detailed Implementation

[0030] The present invention will now be described in further detail with reference to specific embodiments and the accompanying drawings. It should be emphasized that the following description is merely exemplary and is not intended to limit the scope and application of the present invention.

[0031] Non-limiting and non-exclusive embodiments will be described with reference to the following figures, wherein the same reference numerals denote the same parts unless otherwise specifically stated.

[0032] A device for preparing composite hammerheads for medium and large hammer crushers using medium-frequency induction heating, such as... Figures 1-9 As shown, the system includes: a cylindrical sand box 03, a mobile flatcar 07, a ground-fixed support 08, a lifting mechanism, and a medium-frequency induction heater 04. The cylindrical sand box 03 is mounted on the mobile flatcar 07, and the interior of the cylindrical sand box 03 has a first space 032 for accommodating the hammer head model 02. Specifically, the cylindrical sand box 03 is made of stainless steel plate by welding, with an opening at the top. The thickness of the stainless steel plate is 10-20 mm. The outer diameter of the cylindrical sand box 03 is 200-300 mm larger than the maximum outer dimension d of the hammer head model 02 to be poured, and its height is 400-600 mm higher than the highest outer dimension h of the hammer head model 02 (including the height of the riser 021). In actual production, the riser 021 is used as a pouring system for pouring liquid metal, and it may protrude from the cylindrical sand box 03 because the bottom of the hammer head model 02 is not located at the bottom of the cylindrical sand box 03. Specifically, several lifting lugs 031 can also be provided on the upper end and sides of the cylindrical sand box 03. A mobile flatbed cart 07 is slidably mounted on a concrete foundation 05. A cylindrical sand box 03 is mounted on the mobile flatbed cart 07. Driven by the mobile flatbed cart 07, the cylindrical sand box 03 can move back and forth to enter or exit the intermediate frequency induction heater 04. Specifically, a first chute 051 is provided on the concrete foundation 05, and several guide rails 06 are provided on the bottom surface of the first chute 051. The mobile flatbed cart 07 is mounted on the guide rails 06, allowing the cylindrical sand box 03 to move back and forth within the first chute 051. A ground-fixed bracket 08 is fixedly mounted on the side of the mobile flatbed cart 07. A lifting mechanism is located on the top of the ground-fixed bracket 08. Figure 1 , 6 As shown in Figure 7, the medium-frequency induction heater 04 includes a coil support 042, a heating coil 041, and a support platform 043. The coil support 042 is a cylindrical shape with openings at the top and bottom. The heating coil 041 is insulated from the coil support 042 and is arranged around the side wall of the coil support 042. The middle of the heating coil 041 has a second space 044 for accommodating the cylindrical sand box 03. The support platform 043 is horizontally arranged on the side of the coil support 042 away from the moving flatcar 07. A counterweight 09 is provided on the end of the support platform 043 away from the coil support 042. The medium-frequency induction heater 04 can move up and down under the drive of the lifting mechanism.

[0033] like Figure 1 , 5 As shown in Figure 9, the ground-fixed support 08 includes a horizontal frame 081, two vertical frames 082, and a lifting platform 083. The horizontal frame 081 is set close to the cement foundation 05. The lifting platform 083 is set directly above the horizontal frame 081. The two vertical frames 082 are set between the lifting platform 083 and the horizontal frame 081, supporting the lifting platform 083 from the front and rear sides.

[0034] like Figure 1 , 5 As shown in Figures 6 and 9, the vertical frame 082 is a right-angled trapezoid shape, including a vertical beam 821, an inclined beam 822, and a top beam 823. The vertical beam 821 is a smooth cylinder. Guide sliders 431 are provided on the front and rear sides of the support platform 043. The guide sliders 431 are vertically provided with a second sliding groove 432 that matches the vertical beam 821. Driven by the lifting mechanism, the medium-frequency induction heater 04 can move up and down along the vertical beam 821. Specifically, the horizontal frame 081 is welded together from a front beam 811, a rear beam 812, a left beam 813, and a right beam 814. The two vertical beams 821 are respectively located at the connection between the front beam 811 and the right beam 814, and at the connection between the rear beam 812 and the right beam 814.

[0035] like Figures 5-7 As shown, an optical axis hole 433 is provided on the support platform 043 near the counterweight 09. A guide optical axis 11 is vertically arranged through the optical axis hole 433. Its upper and lower ends are fixed to the lifting platform 083 and the horizontal frame 081, respectively. The center of the guide optical axis 10 and the center of the guide slider 431 are triangularly distributed to ensure the balance of the medium frequency induction heater 04.

[0036] Specifically, the lifting mechanism includes a winch 11, a pulley 12, a wire rope 13, and a controller. The winch 11 and pulley 12 are respectively fixed side-by-side on the top of the ground-fixed support 08 via a first bracket 14 and a second bracket 15. The starting end of the wire rope 13 is fixed to the drum of the winch 11, passes through the pulley 12, and the end is fixed to the support platform 143 near the medium-frequency induction heater 04. The lifting mechanism is controlled by the controller, specifically by connecting a remote controller to the controller and then using the remote controller to control the lifting mechanism. Figures 5-7As shown, the wire rope 13 at the winch 11 passes through the wire hole 434. The distance D between the centerline of the wire rope at the wire hole 434 and the centerline of the coil support 042 of the intermediate frequency induction heater 04 is also typically chosen as D, so as to ensure the left and right balance of the lifting mechanism. In actual production, a first limiter and a second limiter can be respectively set at the upper and lower ends of the vertical beam 821 to control the lifting position of the intermediate frequency induction heater 04.

[0037] The working principle of the above device is as follows: The prepared hammer head model is placed into the cylindrical sand box and fixed. The moving flatcar is controlled to move the cylindrical sand box directly below the heating coil. The winch is controlled to rotate, and the medium-frequency induction heater is moved downward through the pulley, so that the heating coil completely surrounds the side wall of the cylindrical sand box. The medium-frequency induction heater is started and preheated for 3-5 minutes to preheat the hammer handle preform to 600-800℃. The medium-frequency induction heating device is turned off, and the hammer head liquid is poured through the riser. After the pouring is completed, the medium-frequency induction heating device is started again for induction heating for 5-10 minutes. After the heating is completed, the winch is controlled to rotate, driving the medium-frequency induction heater upward until the cylindrical sand box is completely exposed. The moving flatcar is then controlled to move back to the initial position.

[0038] Those skilled in the art will recognize that numerous variations are possible with respect to the above description, and the embodiments and figures are merely for describing one or more specific implementations.

[0039] Although exemplary embodiments of the present invention have been described and illustrated, those skilled in the art will understand that various changes and substitutions can be made thereto without departing from the spirit of the present invention. Furthermore, many modifications can be made to adapt specific situations to the doctrine of the present invention without departing from the central concept of the present invention described herein. Therefore, the present invention is not limited to the specific embodiments disclosed herein, but may include all embodiments and equivalents that fall within the scope of the present invention.

Claims

1. A device for preparing a medium-large hammer crusher composite hammer head by medium-frequency induction heating, characterized in that, The utility model provides a kind of induction heating device for hammerhead, including cylinder sand box, mobile flatcar, ground fixed support, lifting mechanism and intermediate frequency induction heater, the cylinder sand box is set in the mobile flatcar, the first space containing hammerhead model is arranged inside the cylinder sand box;The mobile flatcar is slidably arranged on cement base, the cylinder sand box is arranged on the mobile flatcar, and the cylinder sand box can be moved back and forth to enter or move out of the intermediate frequency induction heater under the driving of the mobile flatcar;The ground fixed support is fixedly arranged on the side of the mobile flatcar;The lifting mechanism is arranged on the top of the ground fixed support;The intermediate frequency induction heater includes coil support, heating coil and support platform, the coil support is the cylinder shape with upper and lower openings;The heating coil is insulated from the coil support, is arranged in the coil support along the side wall of the coil support, and the middle part of the heating coil is surrounded by the second space for accommodating the cylinder sand box;The support platform is horizontally arranged on the side of the coil support away from the mobile flatcar, and the counterweight is arranged on the end of the support platform away from the coil support, and the intermediate frequency induction heater can be moved up and down under the driving of the lifting mechanism.

2. The apparatus for manufacturing a medium-large hammer crusher composite hammer head by medium-frequency induction heating according to claim 1, characterized in that: The cylinder sand box is made of stainless steel plate by welding, and the upper part is open.

3. The apparatus for manufacturing a medium-large hammer crusher composite hammer head by medium-frequency induction heating according to claim 1, characterized in that: A plurality of lifting lugs are arranged on the upper end and the side of the cylinder sand box.

4. The apparatus for manufacturing a medium-large hammer crusher composite hammer head by medium-frequency induction heating according to claim 1, characterized in that: A first sliding groove is arranged on the cement base, a plurality of guide rails are arranged on the bottom surface of the first sliding groove, and the mobile flatcar is arranged on the guide rails, so that the cylinder sand box can move back and forth in the first sliding groove.

5. The apparatus for preparing a medium-large hammer crusher composite hammer head by medium-frequency induction heating according to claim 1, characterized in that: The ground fixed support includes a horizontal frame, two vertical frames and a lifting platform, the horizontal frame is arranged next to the cement base, the lifting platform is arranged directly above the horizontal frame, and the two vertical frames are arranged between the lifting platform and the horizontal frame.

6. The apparatus for manufacturing a medium-large hammer crusher composite hammer head by medium-frequency induction heating according to claim 5, characterized in that: The vertical frame is in the shape of a right trapezoid, including a vertical beam, an inclined beam and a top beam, the vertical beam is smooth and cylindrical, guide sliding blocks are arranged on the front and rear sides of the support platform, a second sliding groove matched with the vertical beam is vertically arranged on the guide sliding blocks, and the intermediate frequency induction heater can move up and down along the vertical beam under the driving of the lifting mechanism.

7. The apparatus for manufacturing a medium-large hammer crusher composite hammer head by medium-frequency induction heating according to claim 6, characterized in that: A light shaft hole is arranged on the support platform near the counterweight, a guide light shaft is vertically arranged through the light shaft hole, the upper end and the lower end of the guide light shaft are fixed to the lifting platform and the horizontal frame respectively, and the center of the guide light shaft and the center of the guide sliding block are in a triangular distribution.

8. The apparatus for preparing a medium-large hammer crusher composite hammer head by medium-frequency induction heating according to claim 1, characterized in that: The lifting mechanism includes a winch, a pulley, a steel wire rope and a controller, the winch and the pulley are fixed side by side on the top of the ground fixed support through a first support and a second support respectively, the steel wire rope is fixed at the beginning end of the drum of the winch, passes through the pulley, and is fixed at the end near the intermediate frequency induction heater on the support platform, and the lifting of the lifting mechanism is controlled by the controller.

9. The apparatus for manufacturing a medium-large hammer crusher composite hammer head by medium-frequency induction heating according to claim 8, characterized in that: The steel wire rope at the winch passes through a wire hole, and the distance from the center line of the steel wire rope at the wire hole to the center line of the coil support of the intermediate frequency induction heater is the same as the distance from the center line of the counterweight to the center line of the steel wire rope at the wire hole.

10. The apparatus for preparing a medium-large hammer crusher composite hammer head by medium-frequency induction heating according to claim 6, characterized in that: First and second limiters can be arranged at the upper and lower ends of the vertical beam respectively to control the lifting limit positions of the medium-frequency induction heater.

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