Targeted at three major technical problems existing in national continuous casting production lines for aluminium ingots before 2001, that is, obvious water ripples on aluminium ingot surfaces, low demoulding rates (70~85%) and poor reliability of the unit, a novel production line is developed for 16t/h continuous casting of aluminium ingots as key problems in science and technology are tackled.
◎ Basic performance parameters:
(1) Production capacity of the casting machine set: Max 18t/h
(2) product weight: 20±1.5kg for ordinary aluminium ingots (in conformity with GB/T1196-93)
Dimension of an aluminium ingot: 805×184×85mm (L×W×H)
Dimension of an aluminium ingot stack: 805×805×935mm (L×W×H)
(3) Compressed air
Piping pressure: 0.7Mpa
Working pressure: 0.5Mpa
Total gas consumption: 75Nm3/h (excluding 40Nm3/h, gas consumption of the packaging machine)
(4) Water supply pressure: 0.2-0.3Mpa
Total water consumption: 200m3/h
(5) Working pressure of the hydraulic system: 6Mpa
(6) Movement speed of moulds: V=3.83m/min (capacity: 16t/h)
Movement speed of cooling machine: V=8.8m/min (381 mm/2.6s)
(intermittent operation)
Movement speed of finished product conveyors: V=9m/min (6 positions)
(7) Supply voltage: 380V; installed power: 40kW
(8) External dimension of the machine: 42,000×6,300×4,200mm
(9) Bottom elevation of the public chute at the aluminium inlet: 1,540mm
◎ Innovation points:
※ The machine is provided with a novel structure of dual function chains, eliminating slow crawling phenomena of the conveyor chain and making sure that it can run steadily; in this way, "water ripples" can be nearly all avoided.
※ The machine is provided with a novel demoulding device and the demoulding rate thus reaches at least; in other words, poor demoulding rates of domestically manufactured equipment of the same kind are improved.
※ A novel electric induction accurate positioning device and an aluminium ingot tipping limiting device are invented, substantially improving reliability of the stacker.
◎ Performance advantages of products:
No obvious "water ripples" can be found on surfaces of aluminium ingots; the demoulding rate is up to 99% and above; stacking can be completed in a neat and compact manner; only 5~6 operators are required every shift; and, its capacity reaches 16~18 t/h.
In December 2005, the 16t/h continuous casting production line for aluminium ingots were identified to be domestically advanced by an appraisal committee under the leadership of Academician Xue Qunji
A work site in Qinghai Qiaotou Aluminum and Power Stock Co., Ltd.
A work site in Aluminum Corporation of China limited, Qinghai Branch
A 16t/h aluminium ingot stacker of a new type
A work site in Western Mining Qinghai Baihe Aluminium Co., Ltd.