A ladle microwave heating roasting device
By directly heating the ladle with a microwave heating baking device, the problems of long cycle, unstable temperature and high energy consumption of traditional baking devices are solved, realizing efficient, energy-saving and environmentally friendly ladle preheating, and improving casting quality and production efficiency.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- 广东金志利科技股份有限公司
- Filing Date
- 2025-05-20
- Publication Date
- 2026-07-24
AI Technical Summary
Traditional ladle baking equipment suffers from problems such as long baking cycles, poor temperature stability, high energy consumption, and significant pollution, making it difficult to achieve high efficiency, energy saving, and precise temperature control.
A microwave heating and baking device is adopted, including a microwave component, a support platform and a lifting cylinder. The ladle is directly heated by a microwave radiating device, and precise temperature control is achieved by combining a temperature sensor and an electrical control cabinet, thereby improving heating efficiency and stability.
This technology achieves high efficiency and energy saving in ladle heating, avoids local overheating, extends the service life of the ladle, reduces pollution, and improves production efficiency and casting quality.
Smart Images
Figure CN224543111U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of casting equipment technology, specifically to a microwave heating and baking device for a ladle. Background Technology
[0002] In the foundry industry, the preheating and baking of ladles is a core process for ensuring production safety and improving casting quality. Since ladles are placed in the external environment before use, they may contain moisture. Therefore, preheating is necessary before loading molten iron. This serves two purposes: firstly, to remove moisture, reduce heat loss from the molten metal, ensure casting quality, and guarantee safe production; secondly, the high temperature of the molten metal can easily cause cracks in the ladle's refractory layer, affecting its service life. Traditional baking methods, such as gas-fired baking and oil-fired baking, suffer from high energy consumption, severe pollution, and complex structures. Furthermore, they exhibit poor heating uniformity and difficulty in precisely controlling preheating time, easily leading to energy waste. While coke oven baking can increase temperature, the combustion process generates large amounts of smoke, dust, and sulfides, seriously violating environmental protection requirements. In addition, traditional technologies generally suffer from insufficient temperature control precision, easily leading to localized overheating or underheating of the ladle, affecting its service life and casting quality.
[0003] In response to the current bottlenecks in ladle baking equipment, such as long baking cycles, poor temperature stability, and low energy efficiency, there is an urgent need to develop a new type of baking equipment that combines high efficiency and energy saving, environmental protection and cleanliness, and precise temperature control. Utility Model Content
[0004] In view of one or more shortcomings of the prior art, the present invention provides a microwave heating and baking device for ladles, which can solve the problems of long baking cycle, poor temperature stability, high energy consumption and high pollution.
[0005] To achieve the above objectives, this utility model adopts one or more of the following technical solutions:
[0006] A microwave heating and baking apparatus for a ladle includes a ladle, a support platform, and a microwave component. The support platform is disposed below the ladle to support the ladle. A through hole is provided on the support platform at a position corresponding to the opening of the ladle to accommodate the microwave component.
[0007] The microwave assembly is located below the support platform and includes a microwave generator, a waveguide, and a microwave divergence device. The microwave divergence device is connected to the microwave generator through the waveguide. The microwave divergence device is located below the through hole and has a lifting cylinder installed at its bottom. The lifting cylinder can drive the microwave divergence device to rise into the through hole and align with the ladle opening to form a sealed heating cavity.
[0008] Preferably, the ladle comprises a steel shell, a refractory layer, and a refractory inner layer arranged sequentially from the outside to the inside. The refractory layer is made of high-alumina refractory bricks, and the refractory inner layer is formed of lightweight high-alumina refractory castable. This allows microwave energy to be concentrated in the refractory inner layer of the ladle, thereby improving thermal efficiency.
[0009] Preferably, the diameter of the through hole is larger than the inner diameter of the refractory inner layer and smaller than the outer diameter of the refractory inner layer, so as to ensure that the support platform provides stable support for the ladle.
[0010] Preferably, the microwave divergence device includes a housing, and a microwave divergence wall is inclinedly arranged inside the housing. A microwave divergence port is formed at the large diameter of the microwave divergence wall, and a microwave inlet is provided at the small diameter of the microwave divergence wall for connection with the waveguide tube. The microwave divergence port is coaxially aligned with the ladle opening. The diameter of the microwave divergence port is larger than the inner diameter of the refractory inner layer, thereby covering the entire ladle opening for microwave heating.
[0011] Preferably, the microwave diverging wall has a trumpet-shaped gradient structure, and the inner wall of the microwave diverging wall is covered with a silicon nitride ceramic layer.
[0012] Preferably, the microwave radiating port is provided with a ceramic fiber sealing sheet, which can prevent liquid droplets or impurity particles in the ladle from falling into the microwave radiating port during the heating process, while not affecting the microwave transmission to the ladle opening.
[0013] Preferably, the microwave dispersion device includes a microwave stirring blade and a drive motor. The microwave stirring blade is disposed inside the microwave dispersion wall, and the drive motor is disposed outside the housing. The output shaft of the drive motor is fixedly connected to the microwave stirring blade.
[0014] Preferably, the microwave assembly further includes a mounting base and a fixing frame, the microwave generator and the drive motor are respectively mounted on the mounting base, and the bottom of the microwave radiating device is fixedly connected to the mounting base through the fixing frame; the mounting base is bolted to the top of the lifting cylinder.
[0015] Preferably, the inner wall of the refractory inner layer is provided with a temperature sensor for detecting the heating temperature of the ladle.
[0016] Preferably, it also includes an electrical control cabinet, which is electrically connected to the temperature sensor and the microwave generator. The electrical control cabinet can automatically control the on / off state of the microwave generator according to the ladle temperature, so as to achieve precise temperature control during ladle baking.
[0017] Preferably, the temperature sensor is a type K thermocouple; the refractory inner layer is provided with at least two temperature sensors to ensure the accuracy of ladle temperature detection, and at the same time to ensure uniform heating of the ladle, thereby achieving the purpose of high efficiency and energy saving.
[0018] Preferably, an asbestos sealing gasket is fixedly installed on the top of the housing around the outer ring of the microwave radiating port to improve the sealing of the heating cavity between the microwave radiating port and the ladle opening.
[0019] Preferably, the microwave generator has a power of 5-30kW and a frequency of 2.45GHz±50MHz.
[0020] By adopting the above technical solution, the beneficial effects of this utility model are as follows:
[0021] 1. This utility model incorporates a microwave component beneath the ladle, enabling direct heating and baking of the interior of the inverted ladle via microwaves. Compared to traditional baking methods, this approach offers higher thermal efficiency, improving baking efficiency and saving energy. It solves the problems of long baking cycles and high energy consumption in existing technologies. Simultaneously, the penetrating power of microwaves ensures stable and uniform heating of the ladle's interior, preventing localized overheating that could lead to cracking of the refractory inner layer and extending the ladle's service life. This overcomes the technical shortcomings of poor temperature stability in existing technologies. Furthermore, microwave heating and baking produces no combustion exhaust emissions, reducing air pollution and making it cleaner and more environmentally friendly.
[0022] 2. This utility model utilizes a support platform to support the inverted ladle during heating and baking. A lifting cylinder drives the microwave component to rise until the microwave radiator aligns with the ladle opening to form a sealed heating cavity. This utilizes microwave heating for high efficiency and energy saving.
[0023] 3. This utility model automates the ladle heating process by connecting the drive motor, temperature sensor, microwave generator and other components through a control cabinet, which greatly reduces the labor intensity of workers and improves production efficiency. Attached Figure Description
[0024] The accompanying drawings, which form part of this specification, are used to provide a further understanding of this utility model. The illustrative embodiments of this utility model and their descriptions are used to explain this utility model and do not constitute an improper limitation of this utility model.
[0025] Figure 1 This is a schematic diagram of the structure of an embodiment of the present utility model;
[0026] Figure 2 This is a front sectional view of an embodiment of the present utility model;
[0027] Figure 3 This is a schematic diagram of the structure of the microwave component after the ceramic fiber sheet is hidden in an embodiment of this utility model;
[0028] Figure 4 This is a schematic diagram of the internal structure of the ladle in an embodiment of this utility model.
[0029] In the diagram: 1. Pouring ladle; 2. Support platform; 3. Microwave assembly; 4. Lifting cylinder;
[0030] 101. Steel shell; 102. Fire-resistant layer; 103. Fire-resistant inner layer;
[0031] 201. Base plate; 202. Support frame; 203. Fixed base; 204. Through hole;
[0032] 301. Microwave generator; 302. Waveguide; 303. Microwave divergence device; 304. Mounting base; 305. Fixture; 3031. Housing; 3032. Microwave divergence wall; 3033. Microwave divergence port; 3034. Microwave inlet; 3035. Microwave stirring blade; 3036. Drive motor; 3037. Ceramic fiber sealing sheet. Detailed Implementation
[0033] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the present invention. Unless otherwise specified, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.
[0034] It should be noted that the terminology used herein is for descriptive purposes only and is not intended to limit the exemplary embodiments according to this invention. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without inventive effort are within the scope of protection of this invention.
[0035] Example 1
[0036] In one typical embodiment of this application, a microwave heating and baking apparatus for ladles is provided, such as... Figure 1-4 As shown, the assembly includes a ladle 1, a support platform 2, and a microwave component 3. The support platform 2 is located below the ladle 1 and is used to support the ladle. A through hole 204 is provided on the support platform at a position corresponding to the opening of the ladle to accommodate the microwave component. The microwave component 3 is located below the support platform 2 and includes a microwave generator 301, a waveguide 302, and a microwave divergence device 303. The microwave divergence device 303 is connected to the microwave generator 301 through the waveguide 302. The microwave divergence device 303 is located below the through hole 204, and a lifting cylinder 4 is installed at its bottom. The lifting cylinder 4 can drive the microwave divergence device to rise into the through hole and align with the opening of the ladle to form a sealed heating cavity.
[0037] With the above structure, during the ladle heating operation, the ladle is placed face down on the support platform. The microwave generator is activated, and microwaves enter the microwave divergence device through a waveguide, directly heating the interior of the ladle. Therefore, the ladle microwave heating and baking device provided in this embodiment can achieve efficient and uniform heating of the ladle through microwave heating technology, significantly improving the energy utilization efficiency of the baking process. This solves the problems of high energy consumption, high pollution, and insufficient temperature control precision in traditional baking methods.
[0038] In this embodiment, as Figure 4 As shown, the ladle 1 comprises, from the outside in, a steel shell 101, a refractory layer 102, and a refractory inner layer 103. The steel shell 101 has a thickness of 10-20 mm to ensure structural strength. The refractory layer 103 is formed by refractory bricks laid on the inner wall of the steel shell 101. The refractory bricks in the refractory layer 102 are made of high-alumina refractory bricks, and the thickness of the refractory layer is 20-50 mm. The refractory inner layer 103 uses a lightweight, high-alumina refractory castable with high refractoriness, formed by crucible tamping and ladle casting, with a thickness of 80-200 mm. This allows microwave energy to be concentrated in the refractory inner layer of the ladle, thereby improving the thermal efficiency during microwave heating. In addition to the materials described in this embodiment, the refractory inner layer can also use other materials that meet the requirements of the ladle, including but not limited to silicon carbide ceramics and corundum-based refractories.
[0039] Specifically, support platform 2 is set on the ground to support the ladle that needs to be baked, combined with Figure 1 and Figure 2 As shown, the support platform 2 includes a base plate 201 and a support frame 202 fixed to the top of the base plate. The bottom of the support frame 202 is fixedly connected to the base plate 201 by bolts or welding, and is reinforced with ribs to ensure the support strength of the support frame, thereby improving the stability of the support platform. During operation, the ladle 1 to be baked is placed upside down on the top surface of the support frame 202, with the opening of the ladle 1 facing downwards. At the same time, a through hole 204 corresponding to the shape of the ladle opening is opened on the top of the support frame 202, and the ladle 1 is placed in the through hole 204. In this embodiment, as shown... Figure 2 As shown, the through hole 204 is circular, with a diameter larger than the inner diameter of the refractory inner layer and smaller than its outer diameter. When the ladle is placed upside down on the support platform, the through hole aligns with the entire ladle opening, forming a sealed heating chamber. Simultaneously, the top plane of the support platform contacts the ladle surface, providing stable support and ensuring the stability of the ladle during heating.
[0040] In a preferred embodiment of this application, the through hole and the ladle opening are coaxially aligned, which can be achieved by setting up a ladle lifting point on a crane in the workshop. This ensures uniform stress on the support platform and improves the stability of the support. To guarantee the structural strength of the support platform, it is made of Q355 alloy steel.
[0041] It should be noted that the hoisting assembly that hoists the ladle on the crane and has the function of tilting the ladle is existing technology in the workshop and is not the focus of this application. It will not be described in detail here. For specific implementation methods, please refer to the structures used for tilting or rotating the ladle in existing patents such as CN215033565U, CN208437663U and CN201940594U, or other tooling structures designed according to the actual needs of the factory.
[0042] Specifically, a microwave component 3 is installed below the through hole of the support platform for directly heating the ladle, combined with... Figures 1-3 As shown, the microwave assembly 3 includes a microwave generator 301, a waveguide 302, and a microwave divergence device 303. The microwave generator 301 and the microwave divergence device 303 are connected through the waveguide 302. The microwave generator is the core component for generating microwaves and can convert electrical energy into microwave energy through structures such as magnetrons. The power and stability of the microwave generator directly affect the heating effect and efficiency of the baking device. In this embodiment, the power of the microwave generator is adjustable from 5-30kW, and the operating frequency is 2.45GHz±50MHz. High power is used for rapid heating in the early stage of baking, and the power is switched to low power to maintain a steady state when the target temperature is approached, which reduces energy consumption and avoids the problem of local overheating caused by excessive power. Furthermore, the microwave generator can be adapted to heat ladles of different sizes by adjusting the power.
[0043] In this process, the electromagnetic waves generated by the microwave generator are transmitted to the microwave divergence device via a waveguide. The microwave divergence device then transmits the microwaves generated by the microwave generator to the heating cavity, thereby heating the ladle. Figure 2 and Figure 3As shown, the microwave divergence device 303 includes a housing 3031, a microwave divergence wall 3032, a microwave divergence port 3033, and a ceramic fiber sealing sheet 3037. The housing 3031 is coaxially arranged with the through hole 204 of the support platform, and the outer diameter of the housing is slightly smaller than the inner diameter of the through hole, ensuring that the microwave divergence device can smoothly rise to the support platform. The microwave divergence wall 3032 is inclinedly arranged inside the housing 3031. The microwave divergence wall has a longitudinally tapered trumpet-shaped structure, with a microwave inlet 3034 on its small-diameter surface. The microwave inlet 3034 is connected to the waveguide 302, which in turn connects to the microwave generator 301. The microwave divergence port 3033 is formed at the large-diameter portion of the microwave divergence wall and is located at the top of the microwave divergence wall. During the baking and heating of the ladle, the microwave divergence port is opposite to and aligned with the ladle opening, forming a sealed heating cavity, thereby preventing microwave leakage and improving microwave thermal efficiency and ladle heating efficiency. The ceramic fiber sealing sheet 3037 is fixedly installed at the microwave radiating port 3033 to prevent liquid droplets or impurity particles in the ladle from falling into the microwave radiating port during the heating process, while not affecting the microwave transmission to the ladle opening, thus improving the overall reliability of the device.
[0044] It should be noted that the sealed heating cavity in this embodiment is intended to create a sealed space for microwave transmission, thereby preventing leakage and improving heating efficiency. The ceramic fiber sealing sheet does not affect microwave transmission and therefore does not contradict the sealed heating cavity.
[0045] Furthermore, the cross-sectional shape and inner diameter of the microwave divergence port correspond to the opening of the ladle. In this embodiment, for example... Figure 3 As shown, the microwave divergence port 3033 has a circular cross-section. The inner diameter of the microwave divergence port is larger than the inner diameter of the refractory inner layer of the ladle and smaller than the outer diameter of the refractory inner layer. At the same time, the inner diameter of the microwave divergence port is smaller than the inner diameter of the through hole and the outer diameter of the shell, so as to ensure that the microwave enters the ladle opening more concentratedly and improve the heating efficiency of the ladle.
[0046] To improve microwave heating efficiency, this embodiment also includes a microwave stirring device, such as... Figure 2 and Figure 3 As shown, the microwave stirring device includes a drive motor 3036 and microwave stirring blades 3035. The drive motor 3036 is located below the housing, and the microwave stirring blades 3035 are disposed inside the microwave divergence wall. The output shaft of the drive motor 3036 is connected to the blade shaft of the microwave stirring blades 3035, thereby driving the microwave stirring blades to rotate and stir the electromagnetic waves entering from the microwave inlet 3034, so that the microwaves are quickly dispersed and evenly distributed, flowing out from the microwave divergence outlet to heat the ladle. In this embodiment, the number of blades in the microwave stirring blades is 4. In other embodiments, the number can be set according to actual needs, and this application does not limit this.
[0047] Considering that workers might place other components on the support platform when the ladle is not in place, potentially damaging the microwave radiating device, this embodiment also includes a lifting cylinder 4. This cylinder is used to retract the microwave radiating device after the ladle baking operation is completed, and to raise it into the through hole to connect with the ladle during the baking operation, thereby protecting the microwave components. Specifically, in conjunction with... Figure 1 and Figure 2 As shown, the lifting cylinder 4 is a dual-axis cylinder, which is fixedly mounted on the base plate 201. The top of the lifting cylinder 4 is connected to the mounting base 304 of the microwave component by bolts, so as to fix the microwave component on the lifting cylinder and facilitate disassembly.
[0048] In a preferred embodiment, an asbestos sealing gasket is provided on the outer plane of the microwave radiating port at the top of the housing to improve the sealing of the heating cavity between the microwave radiating port and the ladle opening, prevent microwave leakage, and further improve the efficiency of microwave heating.
[0049] In a preferred embodiment, to more accurately control the preheating and baking temperature of the ladle, a temperature sensor and an electrical control cabinet are also provided. The temperature sensor is connected to the electrical control cabinet via a wire. The temperature sensor is installed on the inner wall of the refractory inner layer to monitor the temperature inside the ladle in real time. The electrical control cabinet, acting as the intelligent control center, is electrically connected to both the microwave generator and the drive motor. The cabinet integrates a PID temperature controller, an audible and visual alarm, and a human-machine interface. The PID temperature controller receives the temperature signal from the temperature sensor in real time and dynamically adjusts the output power of the microwave generator and the speed of the drive motor to achieve closed-loop control of the baking temperature. The audible and visual alarm triggers an alarm when the temperature exceeds the limit or the equipment malfunctions, ensuring operational safety. The human-machine interface supports preset baking curves, including parameters such as heating rate, target temperature, and holding time, and displays the baking status, temperature curve, and energy consumption data in real time. Operators can remotely monitor the entire baking process through the interface.
[0050] The temperature sensor can be a needle-shaped K-type thermocouple with a sensing diameter of Φ8mm and a length of approximately 1m. Its temperature measurement range is below 1300℃. Since the baking temperature of the ladle generally does not exceed 1000℃, it can be directly inserted into the refractory inner layer of the ladle for measurement. After the ladle baking process is completed, it can be removed before hoisting, without affecting the subsequent reception of molten metal and quantitative casting. At least two temperature sensors should be installed to ensure accurate ladle temperature detection and to ensure uniform heating, thereby achieving high efficiency and energy saving.
[0051] The workflow of this embodiment is as follows:
[0052] The ladle is hung on the overhead crane hook above the ladle heating station. The crane then places the ladle upside down onto the support platform, with the ladle opening positioned at the through hole on the platform. The lifting cylinder is activated, lifting the microwave assembly upwards until the microwave radiator aligns with the ladle opening, forming a sealed heating cavity and ensuring concentrated microwave energy on the ladle's inner wall. The microwave generator and drive motor are activated via the control cabinet. Microwaves enter the microwave radiator wall through the waveguide and are evenly dispersed onto the ladle's inner wall by the microwave stirring blades, achieving rapid heating of the ladle. Simultaneously, the control cabinet adjusts the microwave power in real-time based on temperature data from the temperature sensor, ensuring the temperature rises according to the preset curve. This precise temperature control during ladle heating and baking ensures the quality of the subsequent castings.
[0053] It should be noted that the above embodiments are only used to illustrate the technical solution of this utility model, and are not intended to limit it. Those skilled in the art should understand that this utility model can have various modifications and variations. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.
Claims
1. A microwave heating and baking apparatus for ladles, characterized in that, It includes a ladle, a support platform, and a microwave component. The support platform is located below the ladle and is used to support the ladle. A through hole is provided on the support platform at a position corresponding to the opening of the ladle to accommodate the microwave component. The microwave assembly is located below the support platform and includes a microwave generator, a waveguide, and a microwave divergence device. The microwave divergence device is connected to the microwave generator through the waveguide. The microwave divergence device is located below the through hole and has a lifting cylinder installed at its bottom. The lifting cylinder can drive the microwave divergence device to rise into the through hole and align with the ladle opening to form a sealed heating cavity.
2. The microwave heating and baking apparatus for ladles as described in claim 1, characterized in that, The ladle comprises a steel shell, a refractory layer, and a refractory inner layer arranged sequentially from the outside to the inside. The refractory layer is made of high-alumina refractory bricks, and the refractory inner layer is made of lightweight high-alumina refractory castable.
3. The microwave heating and baking apparatus for ladles as described in claim 2, characterized in that, The microwave divergence device includes a housing, and a microwave divergence wall is inclinedly arranged inside the housing. A microwave divergence port is formed at the large diameter of the microwave divergence wall, and a microwave inlet is provided at the small diameter of the microwave divergence wall for connection with the waveguide tube. The microwave divergence port is coaxially aligned with the ladle opening. The diameter of the microwave divergence port is larger than the inner diameter of the refractory inner layer.
4. The microwave heating and baking apparatus for ladles as described in claim 3, characterized in that, The microwave diverging wall has a trumpet-shaped, gradually changing structure, and the inner wall of the microwave diverging wall is covered with a silicon nitride ceramic layer.
5. The microwave heating and baking apparatus for ladles as described in claim 3, characterized in that, The microwave radiating port is equipped with a ceramic fiber sealing sheet.
6. The microwave heating and baking apparatus for ladles as described in claim 3, characterized in that, The microwave radiating device also includes a microwave stirring blade and a drive motor. The microwave stirring blade is disposed inside the microwave radiating wall, and the drive motor is disposed outside the housing. The output shaft of the drive motor is fixedly connected to the microwave stirring blade.
7. The microwave heating and baking apparatus for ladles as described in claim 1, characterized in that, The microwave assembly also includes a mounting base and a fixing frame. The microwave generator is mounted on the mounting base, and the bottom of the microwave emitting device is fixedly connected to the mounting base via the fixing frame. The mounting base is fixedly connected to the top of the lifting cylinder by bolts.
8. The microwave heating and baking apparatus for ladles as described in claim 2, characterized in that, The inner wall of the refractory inner layer is equipped with a temperature sensor to detect the heating temperature of the ladle.
9. The microwave heating and baking apparatus for ladles as described in claim 8, characterized in that, It also includes an electrical control cabinet, which is electrically connected to the temperature sensor and the microwave generator.
10. The microwave heating and baking apparatus for ladles as described in claim 8, characterized in that, The temperature sensor is a type K thermocouple.