High-efficiency multifunctional mechanical stirring device for metal smelting

Abstract

The present invention relates to a high-efficiency multifunctional mechanical stirring device for metal smelting, comprising a base, a driving mechanism, a stirring mechanism, a cooling mechanism, a flue gas treatment device, and a control system. The driving mechanism drives a stirring rod to rotate by means of a motor and a speed reducer, and stirring blades have adjustable angles, thereby ensuring suitability for various smelting processes. The cooling mechanism uses a circulating cooling system, thereby effectively preventing apparatus overheating. The flue gas treatment device is configured to process harmful gases generated during smelting, thereby ensuring environmental compliance. The control system monitors an apparatus status in real time, automatically adjusts operating parameters, and realizes intelligent operation. The device improves smelting efficiency, reduces energy consumption, enhances environmental-friendly performance, and is suitable for smelting metals such as aluminum, copper, and steel.

Description

A high-efficiency, multi-functional mechanical stirring device for metal smelting Technical Field

[0001] This invention relates to the field of metal smelting technology, and more specifically to a high-efficiency, multi-functional mechanical stirring device for metal smelting. Background Technology

[0002] Metal smelting is a crucial step in materials science and industrial production, involving the extraction and purification of metals from ores and the preparation of alloys. To improve the efficiency of the smelting process and the quality of the final product, stirring is essential. Stirring devices use mechanical motion to thoroughly mix molten metal with additives, promoting chemical reactions, accelerating mass and heat transfer, and preventing stratification and localized overheating of the molten metal. However, existing stirring devices still have some significant technical defects and limitations in practical applications.

[0003] First, existing stirring devices are energy-intensive and inefficient. Traditional smelting stirring devices mostly adopt a fixed speed and simple stirring blade design, which cannot be adjusted according to the needs of different smelting processes. This "one-size-fits-all" design makes the energy utilization efficiency of the stirring process low, and it is easy to over-stir or under-stir, resulting in prolonged smelting time, increased energy consumption, and increased production costs.

[0004] Secondly, the agitation equipment lacks versatility. The smelting processes for different metals and alloys vary significantly, requiring different stirring speeds, intensities, blade shapes, and materials. For example, aluminum smelting requires relatively slow and uniform stirring to prevent oxidation, while magnesium alloys require rapid and efficient mixing to ensure uniform alloy composition. Most existing equipment is single-purpose and cannot meet the needs of various metal smelting processes. This lack of versatility not only limits the equipment's application range but also increases the smelter's equipment investment and maintenance costs.

[0005] Furthermore, the durability and maintenance difficulty of the equipment cannot be ignored. During the smelting process, the stirring device is usually in a high-temperature, highly corrosive working environment. Traditional materials (such as ordinary carbon steel) are prone to thermal fatigue and chemical corrosion, leading to a shortened equipment lifespan. Frequent and difficult equipment maintenance often requires shutdown for large-scale overhauls or component replacement, further increasing the smelter's operating costs and downtime losses.

[0006] Meanwhile, existing equipment suffers from low automation and insufficient safety performance. Traditional mixing devices often lack intelligent control systems, requiring operators to frequently adjust the equipment's operating status manually. Working in high-temperature environments poses significant safety risks. Furthermore, the lack of timely alarms and self-protection mechanisms in the event of equipment malfunctions can easily lead to equipment damage or personal injury.

[0007] To address the above issues, there is an urgent need in this field for a multifunctional mechanical stirring device that can simultaneously meet the requirements of high-efficiency stirring, energy-saving operation, adaptability to various smelting processes, high durability, and ease of maintenance. Furthermore, this device should possess a high degree of automation and intelligence, capable of real-time monitoring and adjustment of key parameters in the smelting process to ensure the safe and reliable operation of the equipment. Summary of the Invention

[0008] To address the aforementioned problems, this invention provides a device that is capable of efficient stirring, energy-saving operation, adaptability to various smelting processes, high durability, and easy maintenance, and also possesses a high degree of automation and intelligence.

[0009] To achieve the above objectives, the present invention provides the following technical solution, which mainly includes:

[0010] Base: The supporting structure of the device, on which all mechanisms are fixed. The base provides stability to the equipment and supports the installation of the drive mechanism, stirring mechanism, cooling mechanism, and control system.

[0011] Drive mechanism: Includes two sets of drive wheels, reducer, coupling and motor. The drive wheels are mounted on the base, and the shafts of the drive wheels are connected to the reducer via the coupling. The motor is mounted on the upper side of the base and provides rotational power to the stirring mechanism through the reducer.

[0012] The stirring mechanism consists of a smelting furnace, fixed wheels, inlet and outlet ports, a sealing sleeve, a stirring column, and stirring blades. The smelting furnace has two fixed wheels, which are placed on the drive wheel. One end of the smelting furnace has an inlet and outlet port, and the other end is connected to the flue gas treatment device through a sealing sleeve. A stirring column is fixedly connected inside the sealing sleeve, and the stirring column has multiple fixing grooves for installing the stirring blades.

[0013] Stirring blade structure: The stirring blade is installed in the fixing groove via a fixing ring. One end of the stirring blade has an internal thread, which connects with the external thread of the adjusting seat. The adjusting seat is connected to the fixing seat via a fixing pin, allowing the angle of the stirring blade to be adjusted as needed to adapt to different smelting process requirements.

[0014] Cooling mechanism: includes a liquid storage tank, a first cooling jacket, a second cooling jacket, and a circulation pump. The liquid storage tank is connected to the first cooling jacket via a pipe. The first cooling jacket is installed on the outside of the drive wheel. The second cooling jacket is used to cool the outer surface of the motor. The coolant circulates between the cooling jacket and the liquid storage tank through the circulation pump, forming a closed-loop cooling system to prevent the equipment from overheating.

[0015] Flue gas treatment unit: Connected to the sealing sleeve, it is responsible for treating the waste gas generated during the smelting process, ensuring environmental compliance. After being discharged through the sealing sleeve, the flue gas enters the flue gas treatment unit for filtration and purification, reducing environmental pollution.

[0016] Control System: A PLC controller is used, connecting the drive mechanism, stirring mechanism, and cooling mechanism to achieve intelligent control. The control system is connected to temperature, speed, torque, and level sensors, enabling real-time monitoring of the stirring device's operating status and automatic adjustment of operating parameters to ensure stable and efficient operation. Simultaneously, the control system features automated operation and safety protection functions, and can achieve remote monitoring and data analysis.

[0017] As can be seen from the above technical solution, compared with the prior art, the beneficial effects of the present invention are as follows:

[0018] (1) High-efficiency stirring: By optimizing the design of the stirring blade structure and the adjustable stirring angle, the molten metal and additives are fully mixed, thus improving the smelting efficiency.

[0019] (2) Intelligent control: The PLC controller can automatically adjust the operating parameters of the equipment, monitor the equipment status in real time, and provide safety protection, reduce manual operation, and improve the intelligence level of the equipment.

[0020] (3) Energy saving and environmental protection: It integrates a high-efficiency cooling system and flue gas treatment device, which reduces energy consumption, improves the heat dissipation performance of the equipment, and reduces the emission of pollutants generated during the smelting process.

[0021] (4) Modular structure: The stirring blade structure can be replaced and adjusted according to different smelting process requirements, which increases the flexibility and adaptability of the equipment and is suitable for smelting a variety of metals and alloys. Attached Figure Description

[0022] To more clearly illustrate the technical solutions in the embodiments of the present invention 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 embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0023] Figure 1 is a three-dimensional structural diagram of the present invention.

[0024] Figure 2 is a three-dimensional structural diagram of the rear side of the present invention.

[0025] Figure 3 is a three-dimensional structural diagram of the stirring column of the present invention.

[0026] Figure 4 is a three-dimensional structural diagram of the stirring column of the present invention.

[0027] Figure 5 is an exploded view of the three-dimensional structure of the stirring blade of the present invention.

[0028] Figure 6 is an enlarged view of point A in this invention.

[0029] Explanation of reference numerals in the attached drawings: 1-base, 2-drive wheel, 201-reducer, 2011-coupling, 202-motor, 3-smelting furnace, 301-observation window, 302-fixed wheel, 303-inlet / outlet, 304-sealing sleeve, 305-stirring column, 3051-fixed groove, 306-stirring blade, 3061-internal thread, 307-adjusting seat, 3071-fixed pin, 3072-external thread, 308-fixed ring, 3081-fixed seat, 3074-liquid storage tank, 401-first cooling jacket, 402-second cooling jacket, 403-circulating pump, 5-flue gas treatment device. Detailed Implementation

[0030] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. 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.

[0031] Example 1

[0032] A high-efficiency, multi-functional mechanical stirring device for metal smelting, as shown in Figures 1 to 6, includes a base 1, a drive mechanism, a stirring mechanism, a cooling mechanism, a flue gas treatment device 5, and a control system.

[0033] The drive mechanism includes two sets of drive wheels 2, a reducer 201, a coupling 2011 and a motor 202. Two sets of drive wheels 2 are installed on the base 1. The shaft of one of the drive wheels is connected to the reducer 201 through the coupling 2011. The input end of the reducer 201 is provided with a motor 202. The motor 202 is fixedly installed on the upper side of the base 1.

[0034] The stirring mechanism includes a smelting furnace 3, fixed wheels 302, inlet and outlet ports 303, sealing sleeve 304, stirring column 305, and multiple replaceable stirring blade structures. The smelting furnace 3 is provided with two fixed wheels 302, and the smelting furnace 3 is placed on the drive wheel 2 through the fixed wheels 302. The fixed wheels 302 and the drive wheel 2 cooperate with each other. One end of the smelting furnace 3 has an inlet and outlet port 303, and the other end is fixedly connected to the sealing sleeve 304. The sealing sleeve 304 is connected to the flue gas treatment device 5. The stirring column 305 is fixedly connected inside the sealing sleeve 304. The stirring column 305 is provided with multiple fixing grooves 3051 for installing the stirring blade structures.

[0035] The cooling mechanism includes a liquid storage tank 4, a first cooling jacket 401, a second cooling jacket 402, and a circulation pump 403. The liquid storage tank 4 is connected to the first cooling jacket 401 through a pipe. The first cooling jacket 401 is installed on the outside of the drive wheel 2. The first cooling jacket 401 is connected to the second cooling jacket 402. The second cooling jacket 402 is connected to the liquid storage tank 4 through a pipe and the circulation pump 403 to form a circulating cooling circuit.

[0036] The control system uses a PLC controller, which is connected to the drive mechanism, stirring mechanism and cooling mechanism. The PLC controller is also connected to temperature sensor, speed sensor, torque sensor and liquid level sensor to monitor the operating status of the stirring device in real time and realize automated operation and safety protection.

[0037] To further optimize the above scheme, the smelting furnace 3 is provided with an observation window 301 for monitoring the internal condition during the smelting process.

[0038] To further optimize the above solution, the stirring column 305 is provided with multiple fixing grooves 3051 for detachably installing multiple stirring blades 306. The stirring blades 306 are spiral, flat, or arc-shaped to adapt to different smelting process requirements.

[0039] To further optimize the above scheme, the stirring blade 306 is connected to the external thread 3072 on the adjusting seat 307 via the internal thread 3061. One end of the adjusting seat 307 is connected to the fixed seat 3081 via the fixing pin 3071. The angle of the adjusting seat 307 is adjustable to optimize the stirring effect.

[0040] To further optimize the above scheme, the fixed wheel 302 cooperates with the drive wheel 2 so that the smelting furnace 3 can move along the rotation direction of the drive wheel 2, which facilitates the feeding and discharging of smelting materials.

[0041] To further optimize the above scheme, the first cooling sleeve 401 in the cooling mechanism is installed on the outside of the drive wheel 2 to cool the outer surface of the drive wheel 2, and the second cooling sleeve 402 is used to cool the outer surface of the smelting furnace 3 to prevent the equipment from overheating.

[0042] To further optimize the above scheme, the liquid storage tank 4 forms a closed-loop cooling system with the first cooling jacket 401 and the second cooling jacket 402 through the circulation pump 403 set on the base 1, so as to ensure the circulation of coolant and reduce energy consumption.

[0043] To further optimize the above scheme, the flue gas treatment device 5 is connected to the smelting furnace 3 through the sealing sleeve 304 to treat the waste gas and harmful substances in the smelting process, so as to improve the environmental protection performance.

[0044] To further optimize the above scheme, the materials of the stirring blade 306, stirring column 305 and smelting furnace 3 are high-temperature alloy materials, including nickel-based alloys, stainless steel or titanium alloys, to improve the high-temperature resistance and corrosion resistance of the device.

[0045] To further optimize the above scheme, the control system interacts with the operator through a human-machine interface or a remote monitoring module, displays the operating status of the device in real time, and allows the operator to set operating parameters or make manual interventions.

[0046] Example 2

[0047] This embodiment introduces the practical application of the stirring device in the aluminum alloy smelting process, demonstrating the entire process from device startup, operation, flue gas treatment to smelting completion. It particularly emphasizes how to optimize the aluminum alloy smelting process through intelligent control and cooling system of the equipment.

[0048] 1. Start-up and Preparation Phase

[0049] Equipment Status Check: Before operation, the operator uses the PLC control system to check the status of the equipment. Sensors monitor the temperature, speed, liquid level, and coolant circulation of the stirring device to ensure the equipment is in normal operating condition.

[0050] Start the cooling system: Start the circulation pump 403 in the cooling mechanism to pump the coolant from the storage tank 4 to the first cooling jacket 401 and the second cooling jacket 402. At this time, the first cooling jacket is installed on the outside of the drive wheel 2 to ensure that the stirring device will not overheat under high temperature conditions, while maintaining the temperature stability of the drive mechanism.

[0051] Equipment initialization: The PLC controller loads preset smelting process parameters (such as stirring speed, stirring blade angle and cooling water flow rate) to ensure that the system is ready.

[0052] 2. Smelting process begins

[0053] Adding aluminum raw materials: Aluminum raw materials are added to the smelting furnace 3 through the inlet / outlet 303. The smelting furnace 3 is connected to the sealing sleeve 304 to ensure that the flue gas does not escape during the smelting process.

[0054] Start the drive system: The PLC controller issues a command to start the motor 202 in the drive mechanism, which drives the stirring column 305 to rotate through the reducer 201 and coupling 2011. At this time, the stirring blades 306 on the stirring column 305 start working, uniformly mixing the aluminum raw material with the alloying elements.

[0055] Adjustment of the stirring blade structure: The angle of the stirring blades is adjusted according to the requirements of aluminum alloy smelting. The stirring blade 306 is connected by the internal thread 3061 and the external thread 3072 on the adjusting seat 307. The angle is adjusted to ensure the best mixing effect.

[0056] 3. Intelligent control and optimized operation

[0057] Real-time monitoring and adjustment: During the smelting process, the PLC control system monitors the furnace temperature, stirring speed, cooling water flow rate, and torque changes generated during smelting in real time through sensors. Based on this feedback data, the system automatically adjusts the speed and angle of the stirring blades to ensure thorough mixing of the molten metal and additives, and to prevent over- or under-mixing.

[0058] Cooling system optimization: The cooling system maintains stable temperatures for the smelting furnace and drive system through the first cooling jacket 401 and the second cooling jacket 402. The PLC controller dynamically adjusts the flow rate and circulation speed of the coolant based on data from the temperature sensor to ensure that the system is neither too cold nor too hot, thereby optimizing energy consumption.

[0059] 4. Flue gas treatment

[0060] Flue gas collection and treatment: During the aluminum alloy smelting process, the waste gas generated is guided to the flue gas treatment device 5 through the sealing sleeve 304. The flue gas first enters the primary filtration system, which filters out large particles of dust and metal oxides.

[0061] Cooling and Fine Purification: Before entering further treatment, the flue gas, after primary filtration, is cooled by a cooling system. It then enters an electrostatic precipitator and desulfurization unit to remove fine particles and sulfides, ensuring that the emitted gases meet environmental protection requirements.

[0062] Emissions Detection: The treated flue gas is monitored by a detection system to check the content of pollutants such as particulate matter, sulfur dioxide, and nitrogen oxides. If emissions exceed the standards, the PLC system will adjust the operating status of the treatment unit or issue an alarm signal.

[0063] 5. The smelting process is complete.

[0064] Stop stirring: After the aluminum alloy smelting is completed, the PLC control system gradually reduces the speed of the stirring blades to avoid damage to the equipment caused by the sudden stop of the stirring device.

[0065] Shutting down the drive system: After the stirring process has completely stopped, the control system sends a stop signal to shut down the motor 202 and the reducer 201, and the stirring column 305 stops rotating.

[0066] Stop the cooling system: When the system temperature drops to a safe range, the PLC control system automatically stops the circulating pump 403 and stops the circulation of coolant, completing the cooling process.

[0067] 6. Data Recording and Analysis

[0068] Data storage: The PLC control system records key data such as temperature, rotation speed, and coolant flow rate in real time during the smelting process, which facilitates subsequent analysis and optimization of process parameters.

[0069] Process optimization suggestions: Based on historical data and smelting results, the system automatically generates process optimization suggestions, such as adjusting the angle of the stirring blades and optimizing the cooling time, to provide a reference for the next aluminum alloy smelting.

[0070] 7. Equipment cleaning and maintenance

[0071] Equipment Cleaning: After smelting, operators inspect the interior of the smelting furnace through observation window 301 to confirm that there are no residues. Residual aluminum alloy materials and additives are then removed through inlet / outlet ports 303.

[0072] Routine maintenance: Inspect the operating condition of the agitator blades 306, drive wheel 2, and cooling system to ensure the equipment is in optimal condition before the next operation. Replace worn or damaged agitator blades and clean the flue gas treatment unit 5 regularly.

[0073] Summary of advantages

[0074] High-efficiency mixing and low energy consumption: The stirring device optimizes the angle and speed of the stirring blades through an intelligent control system, which improves the efficiency of the smelting process, while reducing energy consumption by optimizing the cooling system.

[0075] Improved environmental performance: The efficient flue gas treatment system effectively removes harmful substances generated during the smelting process, meeting environmental standards and reducing environmental pollution.

[0076] Automation and intelligent control: The PLC control system enables full automation of smelting operations and can adjust process parameters based on real-time feedback data, reducing the complexity of manual operation and improving the stability of equipment operation.

[0077] This embodiment demonstrates the application of a highly efficient and multifunctional mechanical stirring device in the aluminum alloy smelting process, focusing on its efficient stirring, cooling, and flue gas treatment functions. Through intelligent control, the smelting process is not only more efficient and environmentally friendly, but also the equipment operates more stably, and the smelting process parameters can be optimized, bringing significant economic and environmental benefits to users.

[0078] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. For the apparatus disclosed in the embodiments, since they correspond to the methods disclosed in the embodiments, the description is relatively simple; relevant parts can be referred to the method section.

[0079] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A high-efficiency, multi-functional mechanical stirring device for metal smelting, comprising a base (1), a drive mechanism, a stirring mechanism, a cooling mechanism, a flue gas treatment device (5), and a control system, characterized in that: The drive mechanism includes two sets of drive wheels (2), a reducer (201), a coupling (2011) and a motor (202). Two sets of drive wheels (2) are installed on the base (1). The shaft of one of the drive wheels is connected to the reducer (201) through the coupling (2011). The input end of the reducer (201) is provided with a motor (202). The motor (202) is fixedly installed on the upper side of the base (1). The stirring mechanism includes a smelting furnace (3), fixed wheels (302), inlet and outlet (303), sealing sleeve (304), stirring column (305), and multiple replaceable stirring blade structures. The smelting furnace (3) is provided with two fixed wheels (302). The smelting furnace (3) is placed on the drive wheel (2) through the fixed wheels (302). The fixed wheels (302) cooperate with the drive wheel (2). One end of the smelting furnace (3) is provided with an inlet and outlet (303), and the other end is fixedly connected to the sealing sleeve (304). The sealing sleeve (304) is connected to the flue gas treatment device (5). The stirring column (305) is fixedly connected inside the sealing sleeve (304). The stirring column (305) is provided with multiple fixing grooves (3051) for installing the stirring blade structures. The cooling mechanism includes a liquid storage tank (4), a first cooling jacket (401), a second cooling jacket (402), and a circulation pump (403). The liquid storage tank (4) is connected to the first cooling jacket (401) through a pipe. The first cooling jacket (401) is installed on the outside of the drive wheel (2). The first cooling jacket (401) is connected to the second cooling jacket (402). The second cooling jacket (402) and the liquid storage tank (4) are connected through a pipe and the circulation pump (403) to form a circulating cooling circuit. The control system uses a PLC controller, which is connected to the drive mechanism, stirring mechanism and cooling mechanism. The PLC controller is also connected to temperature sensor, speed sensor, torque sensor and liquid level sensor to monitor the operating status of the stirring device in real time and realize automated operation and safety protection.

2. The stirring device according to claim 1, characterized in that The smelting furnace (3) is equipped with an observation window (301) for monitoring the internal condition during the smelting process.

3. The stirring device of claim 1, wherein The stirring column (305) is provided with multiple fixing grooves (3051) for detachably installing multiple stirring blades (306). The stirring blades (306) are spiral, flat or arc-shaped to adapt to different smelting process requirements.

4. The stirring device of claim 3, wherein The stirring blade (306) is connected to the external thread (3072) on the adjusting seat (307) via the internal thread (3061). One end of the adjusting seat (307) is connected to the fixed seat (3081) via the fixing pin (3071). The angle of the adjusting seat (307) is adjustable to optimize the stirring effect.

5. The stirring device of claim 1, wherein The fixed wheel (302) cooperates with the drive wheel (2) to enable the smelting furnace (3) to move along the rotation direction of the drive wheel (2), which facilitates the feeding and discharging of smelting materials.

6. The stirring device of claim 1, wherein The first cooling sleeve (401) in the cooling mechanism is installed on the outside of the drive wheel (2) to cool the outer surface of the drive wheel (2), and the second cooling sleeve (402) is used to cool the outer surface of the click (3) to prevent the equipment from overheating.

7. The stirring device of claim 1, wherein The liquid storage tank (4) forms a closed-loop cooling system with the first cooling jacket (401) and the second cooling jacket (402) through the circulation pump (403) set on the base (1), ensuring the circulation of coolant and reducing energy consumption.

8. The stirring device of claim 1, wherein The flue gas treatment device (5) is connected to the smelting furnace (3) through a sealing sleeve (304) to treat the waste gas and harmful substances in the smelting process, so as to improve the environmental protection performance.

9. The stirring device of claim 1, wherein The stirring blades (306), stirring column (305), and smelting furnace (3) are made of high-temperature alloy materials, including nickel-based alloys, stainless steel, or titanium alloys, to improve the high-temperature resistance and corrosion resistance of the device.

10. The stirring device of claim 1, wherein The control system interacts with the operator through a human-machine interface or a remote monitoring module, displays the operating status of the device in real time, and allows the operator to set operating parameters or make manual interventions.

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