System for removing falling molten iron

Abstract

The utility model provides a system for removing fallen molten iron, comprising a receiving hopper which is obliquely arranged at the tail end of a transmission wheel of a machine head of a pig casting machine and is used for receiving fallen molten iron; the scraper knife assembly comprises a scraper knife shaft, a scraper knife arranged on one side of the scraper knife shaft and a scraper blade arranged on the other side of the scraper knife shaft; the two ends of the scraper knife shaft penetrate through the two side edges of the material receiving hopper respectively and are in driving connection with the driving end of the reciprocating driving mechanism so as to drive the scraper knife assembly to reciprocate along the inner wall of the material receiving hopper; the iron collecting hopper is arranged at the lower end of the material receiving hopper and is used for collecting the removed molten iron slag; according to the utility model, molten iron falling from the pig casting machine can be automatically and efficiently removed, the working efficiency is improved, and the personnel injury risk is reduced.

Description

Technical Field

[0001] This utility model relates to the field of cleaning equipment technology, and in particular to a cleaning system for falling molten iron. Background Technology

[0002] When molten iron from the blast furnace is transported via ladle to the molten iron flow channel of the casting machine to begin casting, molten iron will fall below the casting machine head assembly. This causes the molten iron to cool and solidify, adhering to the bottom of the equipment, which is difficult to remove and affects the service life of the equipment. The solidified iron block is heavy and solid, and since the casting machine head is located in a pit, manual cleaning would endanger lives.

[0003] Therefore, there is an urgent need for a system to remove molten iron that has fallen from the casting machine, which can automatically and efficiently remove the molten iron that has fallen from the casting machine. Utility Model Content

[0004] The purpose of this invention is to provide a system for removing molten iron that has fallen from a casting machine, aiming to solve the technical problem that manual cleaning of molten iron falling from a casting machine would endanger life.

[0005] To achieve the above objectives, this utility model provides a system for removing fallen molten iron, comprising:

[0006] The receiving hopper is inclined and set at the end of the drive wheel of the casting iron machine head to catch the falling molten iron;

[0007] A scraper assembly includes a scraper shaft, a scraper disposed on one side of the scraper shaft, and a scraper disposed on the other side of the scraper shaft;

[0008] The reciprocating drive mechanism has two ends of the shovel shaft passing through the two sides of the receiving hopper and being driven by the drive end of the reciprocating drive mechanism to drive the shovel assembly to reciprocate along the inner wall of the receiving hopper.

[0009] The iron collection hopper is located at the lower end of the receiving hopper and is used to collect the molten iron slag that has been removed.

[0010] As a further improvement to the above solution, the reciprocating drive mechanism is one of a hydraulic cylinder drive mechanism, a chain drive mechanism, or a gear and rack drive mechanism.

[0011] As a further improvement to the above solution, the clearing system also includes a ferry device for pushing an empty iron collection hopper to the lower end of the receiving hopper and pushing a full iron collection hopper away from the lower end of the receiving hopper.

[0012] As a further improvement to the above solution, the cleaning system also includes a cooling device for spraying coolant or blowing cold air onto the blade assembly to reduce the temperature of the blade assembly.

[0013] The blade assembly is equipped with an infrared temperature sensor that is communicatively connected to the cooling device, so as to control the opening or closing of the cooling device by the real-time monitored temperature value.

[0014] As a further improvement to the above solution, the cleaning system also includes a visual recognition module, which is used to acquire images of the molten iron slag accumulation in the receiving hopper through an industrial camera, thereby controlling the start and stop of the reciprocating drive mechanism.

[0015] As a further improvement to the above solution, the clearing system also includes a pressure sensor: the pressure sensor is installed on the blade and is used to monitor the blade's operating resistance in real time; and the pressure sensor is communicatively connected to the reciprocating drive mechanism.

[0016] Because this utility model adopts the above technical solutions, the beneficial effects of this application are as follows:

[0017] This utility model provides a system for removing fallen molten iron. The receiving hopper is tilted and positioned at the end of the drive wheel of the casting iron machine head, effectively collecting fallen molten iron and promptly scraping it off. During scraping, the combined structure of the scraper and scraper, along with the reciprocating drive mechanism, achieves a double cleaning effect in a single stroke, significantly improving efficiency compared to traditional manual slag removal and ensuring continuous production of the casting iron machine. It also reduces the life-threatening risks associated with manual cleaning. In some preferred embodiments, a transfer device is also provided, enabling automatic replacement of the iron collection hopper, further reducing the labor intensity and life-threatening risks for workers. In some preferred embodiments, a cooling device and an infrared temperature sensor are also provided. The closed-loop control of infrared temperature measurement and spray cooling stabilizes the working temperature of the scraper assembly within a safe range, preventing equipment failure caused by high-temperature deformation. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0019] Figure 1 This is a side view schematic diagram of a system for removing molten iron that has fallen, as disclosed in this utility model.

[0020] Figure 2 This is a front view schematic diagram of a system for removing molten iron that has fallen according to this utility model;

[0021] Figure 3 This is a partial front view schematic diagram of a system for removing molten iron that has fallen, as disclosed in this utility model.

[0022] Figure label:

[0023] 1. Receiving hopper; 2. Shovel assembly; 21. Shovel shaft; 22. Shovel; 23. Scraper; 3. Reciprocating drive mechanism; 4. Iron collection hopper; 5. Transfer device; 0. Cast iron machine head drive wheel.

[0024] The realization of the purpose, functional features and advantages of this utility model will be further explained in conjunction with the implementation methods and with reference to the accompanying drawings. Detailed Implementation

[0025] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0026] It should be noted that all directional indicators (such as up, down, etc.) in the embodiments of this utility model are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicator will also change accordingly.

[0027] Furthermore, in this utility model, descriptions involving "first," "second," etc., are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features.

[0028] Furthermore, the technical solutions of the various embodiments of this utility model can be combined with each other, but only if they are based on the ability of a person skilled in the art to implement them. When the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such combination of technical solutions does not exist and is not within the scope of protection claimed by this utility model.

[0029] See Figures 1-3 This utility model provides a system for removing fallen molten iron, comprising:

[0030] The receiving hopper 1 is welded from high-temperature alloy steel plate with an inclination angle of 15°-30°. It is fixed directly below the transmission wheel 0 of the cast iron machine head and is used to receive molten iron that accidentally falls during operation. The inner wall surface of the receiving hopper 1 is coated with a tungsten carbide wear-resistant layer, and a slag discharge port is opened at its bottom, which is connected to the iron collection hopper 4.

[0031] The shovel assembly 2 includes a shovel shaft 21, a crescent-shaped shovel 22 welded to the front end of the shaft, and a rear scraper 23. The cutting edge of the shovel 22 is made of hard alloy overlay welding and maintains a dynamic gap of 2-5mm with the inner wall of the receiving hopper 1. The scraper 23 is an L-shaped manganese steel plate that forms a sealed fit with the bottom surface of the receiving hopper 1. The two ends of the shovel shaft 21 pass through the side wall of the receiving hopper 1 through self-lubricating bearings and are rigidly connected to the output end of the reciprocating drive mechanism 3.

[0032] The reciprocating drive mechanism 3 has two ends of the shovel shaft 21 passing through the two sides of the receiving hopper 1 and being driven by the drive end of the reciprocating drive mechanism 3 to drive the shovel assembly 2 to reciprocate along the inner wall of the receiving hopper 1.

[0033] Iron hopper 4 is located at the lower end of receiving hopper 1 and is used to collect the removed molten iron slag.

[0034] The material receiving hopper 1 of this utility model is inclinedly set at the end of the transmission wheel 0 of the cast iron machine head, which can effectively collect the falling molten iron and scrape it off in time. During scraping, the composite structure of the scraper 22-scraper 23 and the reciprocating drive mechanism 3 achieve a double cleaning effect in a single stroke, which greatly improves the efficiency compared with traditional manual slag cleaning, ensuring continuous production of the cast iron machine. At the same time, it can also reduce the life danger of manual cleaning.

[0035] In a preferred embodiment, the reciprocating drive mechanism 3 is one of a hydraulic cylinder drive mechanism, a chain drive mechanism, or a gear and rack drive mechanism;

[0036] Specifically, the reciprocating drive mechanism 3 can be implemented using the following preferred embodiments:

[0037] Hydraulic cylinder drive:

[0038] The reciprocating drive mechanism 3 is preferably equipped with a double-acting hydraulic cylinder (model SC100-70). The cylinder body is fixed to the side wall support of the receiving hopper 1 at a 30° angle using high-strength bolts. The piston rod end is connected to the blade shaft 21 via a cross-hinged structure. The hydraulic system's working pressure is set to 16-20 MPa, and a displacement sensor is installed to monitor the blade 22's stroke in real time, achieving a control accuracy of ±1.5 mm. Magnetostrictive dampers are installed at both ends of the hydraulic cylinder to achieve flexible braking within 0.3 seconds at the end of the stroke, avoiding mechanical impact.

[0039] Chain drive:

[0040] It adopts a double-row roller chain drive structure. The driving sprocket (module 12, number of teeth 21) is driven by a geared motor, and the driven sprocket is keyed to the blade shaft 21. The chain pitch is 38.1mm, and an automatic tensioning device is set to keep the chain sag ≤2‰. The chain surface is nitrided and coated with a molybdenum disulfide lubricating layer, and a chain box sealing structure is installed to achieve long-term transmission in high-temperature and dusty environments, with a transmission efficiency of over 92%.

[0041] Gear and rack drive:

[0042] The drive mechanism comprises a 40CrNiMoA alloy steel rack (module 8, hardness HRC58-62) and an involute gear (24 teeth, accuracy grade 6) meshing with it. The rack is rigidly connected to the side wall of the receiving hopper 1 via a dovetail guide rail, and the gear shaft is directly connected to a servo motor. An absolute encoder is configured to achieve a positioning accuracy of ±0.5mm. The tooth surface is laser-hardened to form a 0.8mm hardened layer, and the tooth clearance is adjusted to 0.05-0.1mm via an eccentric sleeve.

[0043] A torque limiter (set value 120 N·m) is provided between the drive mechanism and the blade shaft 21. When the slag removal resistance exceeds the limit, the protection will automatically disengage. Each embodiment integrates a temperature sensor at the output end to monitor the working temperature of the drive mechanism in real time and link it with the cooling system.

[0044] In a preferred embodiment, the clearing system further includes a ferry device 5 for pushing an empty iron collection hopper 4 to the lower end of the receiving hopper 1 and pushing a full iron collection hopper 4 away from the lower end of the receiving hopper 1.

[0045] Specifically, the supporting transfer device 5 includes a track, an electric push rod and an RFID identification module. When the weight sensor detects that the iron collection bucket 4 is full, it automatically triggers the transfer device 5 to perform an empty / full bucket replacement operation.

[0046] In this embodiment, the transfer device 5 is arranged laterally along the lower end of the receiving hopper 1 with a guide rail assembly. A sliding push platform is set on the guide rail. The bottom of the push platform is integrated with a bidirectional electric push rod mechanism driven by a servo motor. Electromagnetic clamps are respectively configured at the ends of the push rod stroke. Positioning slots matching the cross section of the receiving hopper 4 are provided at both ends of the guide rail. An RFID radio frequency identification module is embedded in the inner wall of the slot for reading the identification code of the receiving hopper 4.

[0047] During implementation, the working process of the shuttle device 5 is as follows:

[0048] In the initial state, the fully loaded iron collecting hopper 4 is located at the first station directly below the receiving hopper 1, and the empty iron collecting hopper 4 is stationed at the second standby station. When the weight sensor detects that the load of the iron collecting hopper 4 has reached the preset threshold, it sends a replacement signal to the PLC controller. The controller activates the RFID module to verify the identity of the iron collecting hopper 4 at the current station. After confirming that the replacement condition has been met, it starts the drive motor.

[0049] The electric push rod extends to grab the fully loaded iron collection bucket 4 and moves it horizontally along the guide rail to the transfer area via the gripper.

[0050] After the push rod reverses direction, it accurately pushes the spare empty bucket to the bottom of receiving hopper 1. After the positioning sensor sends a signal indicating that the bucket is in place, the replacement cycle is completed.

[0051] This utility model adopts a guide rail-push rod linkage mechanism and RFID identification to work together to ensure accurate positioning of full bucket unloading and empty bucket loading; through the linkage of weight sensor and logic controller, it realizes real-time monitoring and automatic response of load status, which reduces the energy consumption of equipment idling compared with the traditional timed replacement method.

[0052] In a preferred embodiment, the cooling device of the cleaning system is preferably located on the side or above the blade assembly 2, and is connected to the working area of ​​the blade assembly 2 via a pipe or air duct. The cooling device can be a liquid cooling module or an air cooling module. The nozzles of the liquid cooling module are arranged in an array to ensure that the coolant evenly covers the surface of the blade 22; the air cooling module generates directional cold air through a high-pressure fan to blow away the high-temperature areas on the blade assembly 2.

[0053] The infrared temperature sensor is integrated into the root or side of the blade assembly 2, collecting the temperature signal when the blade 22 contacts molten iron in real time, and feeding the temperature data back to the control unit of the cooling device via wired or wireless communication (such as CAN bus or Bluetooth). The control unit has a preset temperature threshold range (e.g., 500℃-800℃). When the infrared temperature sensor detects that the temperature exceeds the first threshold (e.g., 800℃), the cooling device is automatically activated; when the temperature drops below the second threshold (e.g., 500℃), the cooling device is shut down to save energy. Furthermore, the output power of the cooling device can be dynamically adjusted according to the temperature change gradient; for example, when the temperature rise rate exceeds a set value, the coolant flow rate or cold air intensity is automatically increased.

[0054] The temperature of the blade 22 is monitored in real time by an infrared temperature sensor, and the cooling device is started and stopped in combination with threshold control to effectively prevent deformation, wear or coating peeling of the blade 22 due to overheating, thus extending the service life of the blade assembly 2. A compatible design combining liquid cooling and air cooling is adopted, allowing the optimal cooling method to be selected according to working conditions. For example, liquid cooling is prioritized for rapid cooling in scenarios with large amounts of molten iron splashing, while air cooling is switched to avoid liquid contamination in dust-sensitive environments. A dynamic power adjustment strategy based on the rate of temperature change enables rapid response to sudden high-temperature conditions, preventing equipment shutdown due to sudden temperature rises and ensuring the reliability of continuous operation of the cleaning system.

[0055] In a preferred embodiment, the cleaning system further includes a visual recognition module, which is used to acquire images of the molten iron slag accumulation in the receiving hopper 1 through an industrial camera, thereby controlling the start and stop of the reciprocating drive mechanism 3.

[0056] The visual recognition module includes at least one industrial camera, an image processing unit, and a control module. The industrial camera is preferably installed on the side wall or top of the receiving hopper 1, with its lens facing the area where molten iron slag accumulates inside the hopper 1, and is equipped with a high-temperature resistant protective cover to prevent molten slag splashing or heat radiation damage. The shooting frequency of the industrial camera is adjustable, for example, set to an interval of 1-5 frames per second to balance data processing volume and real-time requirements.

[0057] The image processing unit is connected to the industrial camera via wired or wireless communication (such as Ethernet or a 5G module) to perform grayscale analysis, edge detection, and contour recognition on the acquired slag images. Specifically, the image processing unit calculates the real-time volume ratio of the slag accumulation area based on a preset threshold for the molten iron slag accumulation height or coverage area (e.g., 80% of the volume of the receiving hopper 1). When the accumulation ratio is detected to exceed a first preset threshold, a start signal is generated and sent to the control module. When the accumulation ratio is lower than a second preset threshold, a stop signal is generated to shut down the reciprocating drive mechanism 3.

[0058] Furthermore, the control module is linked to the motor controller of the reciprocating drive mechanism 3, controlling the motor's start / stop and operating speed according to the start / stop signal. For example, when the accumulated amount approaches the upper limit of the threshold, the reciprocating drive mechanism 3 can be triggered to operate in high-speed mode; when the accumulated amount decreases to a safe range, it switches to low-speed or standby mode. In addition, the visual recognition module can also be configured with a supplementary lighting device (such as an LED array), which automatically turns on when there is insufficient light in the receiving hopper 1 to ensure the clarity of image acquisition.

[0059] Visual recognition technology is used to monitor the molten iron slag accumulation status in real time, replacing the traditional manual observation or timed start-stop strategy, avoiding overload blockage or idling losses in the receiving hopper 1, and improving the response accuracy and efficiency of the cleaning system.

[0060] In a preferred embodiment, the cleaning system further includes a pressure sensor: the pressure sensor is disposed on the blade 22 for real-time dynamic monitoring of the operating resistance of the blade 22; and the pressure sensor is communicatively connected to the reciprocating drive mechanism 3;

[0061] Specifically, the pressure sensor is preferably a strain gauge type or a piezoelectric thin film type sensor, attached to the root or side stress concentration area of ​​the working surface of the shovel 22, for real-time detection of the lateral shear force or longitudinal pressure when the shovel 22 comes into contact with molten slag. The pressure sensor is fixed to the shovel 22 body by a rigid bracket or embedded mounting groove, and its surface is covered with a high-temperature resistant protective layer (such as a ceramic coating) to resist molten slag splashing and high-temperature corrosion.

[0062] The pressure sensor communicates with the control unit of the reciprocating drive mechanism 3 via a wired signal line or a wireless transmission module (such as ZigBee or Industrial Ethernet). The control unit has a preset resistance threshold range (e.g., 200N-500N). When the pressure sensor detects that the real-time operating resistance exceeds the first threshold (e.g., 500N), it automatically generates a load reduction command, controlling the reciprocating drive mechanism 3 to reduce its output torque or suspend operation. When the resistance falls below the second threshold (e.g., 200N), the drive mechanism resumes normal operation. Furthermore, the operating speed of the drive mechanism can be dynamically adjusted based on resistance changes. For example, when the resistance continues to rise, the control unit reduces the speed of the drive motor by a preset ratio, forming a negative feedback control loop.

[0063] By accurately monitoring the operating resistance of the blade 22 with a pressure sensor, the machine can be stopped or slowed down in time when there is abnormal jamming or overload, avoiding equipment failures such as blade 22 breakage and drive motor burnout, and significantly improving system safety. The output parameters of the drive mechanism are dynamically adjusted according to the resistance, maintaining the operating stability of the blade 22 when the molten iron slag is unevenly distributed or the hardness changes abruptly, reducing the frequency of manual intervention.

[0064] The above are merely preferred embodiments of this utility model and do not limit the patent scope of this utility model. Any equivalent structural transformations made based on the inventive concept of this utility model and the contents of this utility model specification and drawings, or direct / indirect applications in other related technical fields, are included within the patent protection scope of this utility model.

Claims

1. A drop-off molten iron removal system characterized by, include: The receiving hopper is inclined and set at the end of the drive wheel of the casting iron machine head to catch the falling molten iron; A scraper assembly includes a scraper shaft, a scraper disposed on one side of the scraper shaft, and a scraper disposed on the other side of the scraper shaft; The reciprocating drive mechanism has two ends of the shovel shaft passing through the two sides of the receiving hopper and being driven by the drive end of the reciprocating drive mechanism to drive the shovel assembly to reciprocate along the inner wall of the receiving hopper. The iron collection hopper is located at the lower end of the receiving hopper and is used to collect the molten iron slag that has been removed.

2. A drop-out molten iron removal system according to claim 1, wherein The reciprocating drive mechanism is one of a hydraulic cylinder drive mechanism, a chain drive mechanism, or a gear and rack drive mechanism.

3. A system for removing molten iron drops according to claim 1 or 2, characterized in that The clearing system also includes a ferry device for pushing empty iron collection buckets to the lower end of the receiving hopper and pushing full iron collection buckets away from the lower end of the receiving hopper.

4. The drop-off molten iron removal system according to claim 1 or 2, characterized by, The cleaning system also includes a cooling device for spraying coolant or blowing cool air onto the blade assembly to reduce the temperature of the blade assembly. The blade assembly is equipped with an infrared temperature sensor that is communicatively connected to the cooling device, so as to control the opening or closing of the cooling device by the real-time monitored temperature value.

5. The drop-off molten iron removal system according to claim 1 or 2, characterized by, The cleaning system also includes a vision recognition module, which is used to control the start and stop of the reciprocating drive mechanism by acquiring images of the molten iron slag accumulation in the receiving hopper through an industrial camera.

6. The drop-off molten iron removal system according to claim 1 or 2, characterized by, The cleaning system also includes a pressure sensor mounted on the blade for real-time dynamic monitoring of the blade's operating resistance; and the pressure sensor is communicatively connected to the reciprocating drive mechanism.

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