Servo-Driven Sector Ladle for Centrifugal Pipe Casting
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Solution Overview
Problem
The existing water-cooled centrifugal pipe casting machines face challenges in maintaining constant tilting speed of the sector ladle and travel speed, leading to non-uniform wall thickness and overweight issues in casting pipes due to variations in oil temperature and load on the cylinder-driven systems.
Innovation Solution
The implementation of a water-cooled centrifugal pipe casting machine with a sector ladle tilting system driven by a servo motor and a parallel four-bar linkage structure, combined with a variable frequency motor-controlled travel system, ensures constant tilting and traveling speeds through precise control of the sector ladle and pipe mold movements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a cylinder-driven system is used for the sector ladle tilting system and travel system, then the device complexity is reduced, but the manufacturing precision deteriorates due to inability to maintain constant speeds
Solution Approach 1:
The patent replaces the traditional cylinder-driven mechanical system with a servo motor-driven system for the sector ladle tilting mechanism and a variable frequency motor-driven system for the travel system. This substitution enables precise speed control through electronic regulation rather than purely mechanical means, thereby maintaining constant tilting and traveling speeds to ensure uniform wall thickness in casting pipes.
Solution Approach 2:
The patent implements parameter changes by using servo motors and variable frequency motors that can dynamically adjust and maintain constant rotational speeds despite variations in load and oil temperature. The servo motor controls the tilting speed of the sector ladle while the variable frequency motor controls the traveling speed of the pipe mold, ensuring stable casting conditions and uniform wall thickness.
2Ease of operation
If a cylinder-driven system is used for the sector ladle tilting system and travel system, then the ease of operation is improved, but the productivity deteriorates due to speed variations affecting production rate
Solution Approach 1:
The patent replaces the cylinder-driven system with servo motor and variable frequency motor-driven systems that provide both ease of operation through electronic control and constant speed maintenance. This ensures stable production rates by preventing speed fluctuations that would otherwise affect the production rate of quality casting pipes.
3Device complexity
If a cylinder-driven system is used for the sector ladle tilting system and travel system, then the device complexity is reduced, but the loss of substance increases due to waste of hot metal material
Solution Approach 1:
The patent implements parameter changes by using servo motors and variable frequency motors that maintain constant tilting and traveling speeds despite load and temperature variations. This precision control ensures that hot metal is poured and solidified at the correct rates, preventing defects that would lead to scrap and waste of expensive hot metal material.
4Ease of operation
If constant tilting speed and traveling speed are not maintained, then the ease of operation is improved by allowing speed variations, but the manufacturing precision deteriorates causing non-uniform wall thickness
Solution Approach 1:
The patent uses servo motors and variable frequency motors that automatically maintain constant speeds through electronic control systems. These systems detect and compensate for speed variations caused by load changes or oil temperature fluctuations, ensuring uniform wall thickness in the casting pipes without requiring manual intervention or sacrificing operational ease.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration stabilizes the transfer speed and ensures uniform wall thickness of casting pipes, improving their quality and reducing material waste by maintaining consistent metal flow and movement.
Implementation Method 1
The centrifugal casting method is a casting method including pouring liquid metal into a rotating mold, then the liquid metal therein fills the mold under the action of a centrifugal force and solidifies to be a cast product
Implementation Method 2
Water-cooled centrifugal pipe casting machine
Data Source
AI summary
A water-cooled centrifugal pipe casting machine includes a sector ladle tilting system, a pouring runner, a pipe mold and a pipe removing device. The pipe mold is provided to a travel system, and rotation of the pipe mold is controlled by a pipe mold rotating system. By using a servo motor driving the sector ladle tilting system, by using a parallel four-bar linkage structure tilting a sector ladle, and by using a variable frequency motor controlling the movements of a rack and a gear of a travel driving system, a constant amount of hot metal flowing out of the sector ladle per unit time can be ensured and a constant traveling speed of the centrifugal pipe casting machine are achieved. As such, uniformity of the wall thickness of the casting pipes can be ensured, the quality thereof can be improved, and materials required can be saved.