aluminum alloy rod production line--aluminum alloy rod continuous casting and rolling line
FOSHAN METECH ALUMINUM TECHNOLOGY CO.,LTD is the professional manufacturer and exporter of the aluminum alloy rod production line equipment. We could be responsible for the turnkey project of the full aluminum alloy rod continuous casting and rolling line( EC grade aluminum rod continuous casting and rolling line; aluminium alloy rod CCR--continuous casting and rolling line)
MICHAEL TAN
michael @cnmetech.com
86-18664280343 whatapp
metech-michael SKYPE
I.Brief introduction of the aluminum alloy rod production line--continuous casting and rolling line
This aluminum alloy rod continuous casting and rolling production line-- CCR line is applied to produce conductive round aluminum rods, high purity aluminum rods and alloy rods. (1xxx grade rods, part 3xxx, 6xxx, 8xxx, the manufacturing technology should be responsible by the Buyer). It can produce Ф12mm and Ф9.5mm two types of aluminum rods. Ф12mm rod is running by 13 rolling stands; Ф9.5mm running by 15 rolling stands. When making EC grade rods, the speed is about 4-4.5T/h; when making alloy rods (6xxx, 8xxx etc.) is 3.5-4.3T/h.
Flowchart: of the aluminum alloy rod continuous casting and rolling line
Aluminum melting furnace (Introduced by special catalogue) → Four-wheel continuous casting machine → Front puller → Rolling shear → Straighten machine → Bridge → Feeder → Continuous rolling mill → Quenching device → Back puller → Dual-basket coiler → Aluminum rods/ Alloy rods packing machine → Weighing to storage (weighing device is prepared by user)
This production line adopts continuously casting and rolling process. From raw material melting, casting ingot to rolling finished rod, the whole process can be finished in one time without interrupt. The whole machine unit realizes mechatronics operation. This line adopts combination of DC speed regulation and AC transducer speed regulation which has the advantage of high synchronization and efficiency, PLC automatically control and monitor the production line, with color touch screen display & operation, failure warning and automatic stop protection function. The whole production line is working with low cost, stable and in accordance with related national standard and enterprise standard
1. Continuous casting machine
(The pipelines of the cooling water circulation system, pumps and valves should be responsible by the buyer, the seller would offer the related drawings.)
1.1 The continuous casting machine is composed of casting ladle, molten aluminum temperature measuring device, molten aluminum flow & liquid level auto controller, crystallizing wheel and gearing, pinch roller, tension wheel, idle gear, steel tape dryer & water cleaning device, steel strip oiling device, ingot casting approach bridge, water cooling system, water pressure display device, steel strip and air circuit system etc. All the components are installed on the one-piece substructure. All the casting process can achieve automation and equipped with 4kw AC motor with transducer.
1.2 The qualified molten aluminum alloy liquid will flow into up and down casting ladles via launder. The casting ladle is equipped with burner and bricked refractory lining material (will not pollute 99.9%-99.95% molten aluminum). The casting ladle can move up and down, left and right. By liquid level auto controller and pinch roller position adjustment, the Al liquid can casting horizontally into die cavity formed by crystallizing wheel and closed steel strip. The continuous casting machine adopts horizontal casting. The casting system can automatically control liquid level, without manual control or assistance.
1.3 Φ1600mm trapezoid crystallizing wheel is made of Cu-Ag alloy and no sand hole. In order to guarantee the cast ingot crystallization compact and even, the crystallizing wheel adopts four-side spray cooling. During water spray, the water surface will become sector shape. Water control for inside, outside and flank cooling should be sectionalized. Each section water supply can be adjusted individually. All the spray nozzles, inside and outside cooling rings are made of stainless steel. Water control valve with pressure display is also equipped. Using 11 electromagnetic flowmeters to display the flow of cooling water at different sections.
1.4 The cooling system of casting machine adopts closed type. It’s equipped with draught hood (prepared by user). This can suck up the steam caused during the cooling of crystallizing wheel, to avoid bad crystallization caused by air hole and bubble in the Al liquid.
1.5 Steel strip tensioning and compressing are pneumatic, ensure the tension is adjustable. Tensioning wheel and pinch roller must have deviation adjusting device to adjust the steel strips.
1.6 In order to guarantee the aluminum ingot de-mould smoothly, continuous casting machine must have crystallizing wheel oiling device, steel strip dryer and cleaning device.
2. Front puller
The motor of the front puller use frequency control speed adjustment, which has single-unit operation and in-line linkage operation two modes.
The front puller is made up of motor, reduction gearbox, transmission box and up&down rollers. It is mainly used to pull the aluminum blank that come from the casting machine to the rolling shear. So that the rolling shear could cut the unqualified aluminum blank. It in-line with the rolling machine, once the rolling machine was broken, the upper wheel of the front puller would press down and pull the aluminum blank to the rolling shear for cutting and move away.
Diameters of the pulling wheels: Upper wheel: 200mm. Lower wheel: 280mm
3. Rolling shear
The top and bottom cutter heads are driven by a motor dragging a speed reducer. Two cutters are installed respectively up and down on the cutter head. The shearing speed of the cutter point is close to the movement speed of cast ingot. Both cutter heads have roll shearing.
After ingot approaching out, rolling shear start to working and cutting the bad quality ingot to short piece.In the case that the aluminum ingot can meet the requirement of rolling, rolling shear will stop working and ingot will be fed into rolling machine. However, in case of any fault in rolling mill or coiler, rolling shear will start up automatically and cut ingot into short parts, which will fall into a trolley and be taken away.
4. Straightening machine
The straightening machine is five-wheel type. It is equipped with three down fixed wheels and two up move wheels. The move wheels movement is driven by the air cylinder and controlled by electric. Quantity of straightening wheel: upper wheel 2 pcs, lower wheel 3 pcs.
5. Guiding carrier roller
It guides cast ingot transfer by front puller into feeding device, and enter into rolling mill. When rolling mill in normal working, two sets of carrier roller falling down, so does the cast ingot falling down, it mainly adjusts and buffers the distance between ingot and rolling mill, makes ingot less difference pull from casting machine.
6. Induction heater (when making 6xxx alloy rods needed)
6.1 Output power of the induction heater: 350Kw; Output medium-frequency voltage: 700V; Output working frequency: 400-450Hz. It can make the aluminum ingot with constant temperature and roll in constant temperature. The induction heater is mainly consisted of heater, medium-frequency power box, temperature measuring (display in big screen) and controlling system etc. It can meet the processing demand of the aluminum alloy ingot’s heat treatment before rolling, the max heating temperature for aluminum ingot should above 70℃.
6.2 The induction heater device can be moved, when there is no need for it, then can be moved away and used as guiding roller.
6.3 The induction heater is equipped with 60m³/h closed circulating cooling system.
7. Electric cutting saw 1 set
8. Continuous rolling mill (including the hydraulic safety protection cover)
Continuous rolling mill includes DC motor, gear box, active feeding device, continuous rolling mill system, block detection stopping device, hole pattern plug gauge and foundation bolts, etc.
8.1 There is active feeding device at the inlet of rolling mill. The aluminum (aluminum alloy) ingots are clamped by air cylinder and fed to No. 1 rolling stand.
8.2 There are 15 rolling stands. Roll pass is 3-roller Y type. This machine can guarantee better rolling and even deformation, and improve rod elongation and strength.
8.3 The main drive gear of rolling mill adopts inblock cast. Drive gear and rolling stand are made of high strength nodular cast iron which has the advantages of low noise and long service life. The box adopts resin sand mould casting which has the advantages of high strength, high precision and nice appearance.
8.4 Long and short axises of rolling stand adopt 40Cr which has the advantages of high strength and long service life. Roller is made of special material（5CrMnMo）, which has high strength and high precision after hardening & tempering, heat treatment and fine grinding.
8.5 Spiral bevel gear wheel must use high strength alloy steel 20CrMnTi. It will show high precision, meshing good and low noise after hardening, tempering, heat treatment and tooth surface fine grinding.
9. Continuous rolling mill emulsion Lubricating parts (emulsion pipeline and valve, should be provided by buyer, the drawing provided by supplier)
The emulsion lubricating parts provided by supplier: emulsion pump (2 pcs), flanges,40m³/h heat exchanger, 20m³/h heat exchangerHoffman belt type vacuum filter unit.
9.1 The emulsion enter the header pipe on the gear box through centrifugal pump. After lubricating and cooling the gear, roller and guiding of each rolling stand via rubber tube, then the emulsion will back to emulsion pool via reflux tank on the foundation and return pipe. The emulsion temperature must below 60℃.
9.2 One 40m³/h heat exchanger for continuous rolling mill, one 20m³/h heat exchanger for quench cooling. Also share the continuous rolling mill, and share the pool in quench section.
10. Rolling mill oil lubricating parts (oil pipeline and valve, should be provided by buyer)
Two sets of oil supply system provided by supplier (one is for spare use), which includes oil pump, oil filter, and flange.
10.1 The oil will enter oil inlet header pipe on the back of the gear box by oil pump through filter, then enter the gearbox. The nozzle of branch oil pipe will splash lubricate gears and rolling bearings. The oil will return to oil tank from downside of gear box tip through oil return pipe.
10.2 Oil pressure gauge should be assembled on the oil pipe. When the oil pressure is too low, the electrical control will alarm automatically.
11. Quenching coiling take-up device
This take-up device is mainly composed by the following parts: roller deforming device, cooling water pipeline system, cooling drying system, active hauling device, annular rocking beam device, double-spooler coiling trolley, operating deck, etc. This take-up device has the advantages of concise construction, artistic appearance, low failure rate, simple operation and long life.
After the continuous rolling mill, the AL rod passes the roller deforming device, enters into water cooling quenching pipeline system, cooling drying system, which make the AL rod cool down evenly and dry out, then passes through the active hauling device and feeds into annular rocking beam device. By the centrifugal shaking, Al rod drops into the coiling trolley basket. There are big & small loop type take-up and plum blossom type take-up. In order to protect the appearance of AL rod, all transitions of this take-up device have special design to confirm no galled spots on AL rod surface.
The cooling quenching pipeline system has the following two functions: a) cooling and lubricating the guide wheel to avoid the guide wheel to stick AL after special handling; b) cooling and lubricating the AL rod, adjusting the AL rod coiling temperature. The cooling water can be shared with the continuous casting machine, independent design is also acceptable. The cooling water flows through the cooling system & water return manifold system, then returns to the liquid storage tank. Water inlet manifold inflow in section and in branch, every sectional inflow is showed on the pressure gage, there is valve to control in order to cooling evenly, so as to confirm the finished AL rod’s temperature controllable. Step quenching, emulsion is the quenching media. Cooling system pipe is installed with backwater bag and guide wheel. The inflow connections are the anti-corrosive stainless steel. Cooling system pipes is connected with the water return manifold through the above various bags.
A. Idler wheel is used in the roller deforming device, which is good for the AL rod slowly pass through, avoid the friction between rod and arc surface, and promote the rod surface quality.
B. Cooling water pipeline system is composed of inlet valve, pressure meter, backwater bag, stainless steel fastenings, etc.
C. Cooling drying system is mainly used for drying the remaining water of AL rod surface. It is mainly used in take-up process, to confirm uniform heat dissipation of the AL rod, ensure consistent physical properties of inner and outer, up and down parts.
D. Active hauling device adopts the active double pinching, use the spring to adjust the pressure, to confirm the synchronism.
E. Annular rocking beam device is driven by AC motor, use the reduction gearbox to reduce the drive, frequency control. Low speed rolls big circle, high speed rolls small circle, wind into bunch in the take-up basket of the trolley.
F. Coiling trolley is driven by gear head motor. There are two take-up baskets in the deck. When the right basket is full, the operator will press the button in the operation desk to change the basket.
12. Electrical control system requirements
12.1 Electrical control cabinet will be put into specialized electrical distribution room (supplied by the user). Only casting machines, rolling machines and rod rewinding operation device will be assembled in the production site. Electrical control cabinet is neat in appearance and easy for wire connecting.
12.2 Transmission for continuous casting machines in the production line, front hauling machine, rolling shear, continuous rolling mill, rod coiling / taking up device are controlled synchronously by Siemens PLC. Control parts adopt PLC + touch screen to conduct and coordinate the whole system work. All speed adjusting devices (operation units or HMI 10" touch screen) have two control modes (single machine & linkage).
12.3Under the mode of single-machine-control, casting machine, forward hauling, rolling shear, continuous rolling mill, backwards hauling and rod take-up speed can be adjusted individually by the HMI or operation desk.
12.4 Under the mode of linkage-control, the speed of hauling, straightening, rolling mill and rod winding drive motor track the speed of the casting machine automatically. The whole line speed subject to the casting machine speed and control synchronously in proportion, calibrate and compensate the speed error. (Every motor is equipped with the linkage speed fine-tuning).
12.5 PLC adopts Siemens S7-200 series. Whole control system adopts PLC auto control plus manual control. Casting machine and rolling machine use the same one operation desk, besides human-computer interface, it is equipped with common buttons control.
12.6 Touch screen adopts color touch screen HMI to operate. Whole production process flow adopts flash display, meanwhile, cooling system, lubrication system and locked rolling alarm system also have flash display, which is easy to send out operational command and inspect the operation of the machines. Touch screen functions: Monitoring and display various kinds of running parameters. Process parameters can be setup, modified and displayed by HMI. Debugging function is also included.
12.7 HMI touch screen exchanges data with PLC, realize monitor and control the system by PLC program. PLC exchanges data in two-way with each transmission by AC frequency converter/ DC speed-adjusting device, monitor and inspect each device unit status.
12.8 System can give sound and light alarm against main machine over-current, over-voltage and under-voltage, and realize auto-protection. There will be indications on abnormal current or motor speed. If continuous rolling machine is locked rolling, alarm will be sent out automatically and the machine will stop automatically.
* * * IMPORTANT NOTICE * * *
All the images and attached drawings are only for reference, which should not be implemented as the basis of the contract for specific design and manufacturing.
EQUIPMENT SUPPLYING LIST
I. Four-wheel continuous casting machine: 1 set (below Qty for unit set)
1. The base of continuous casting machine 1 set
2. Tension wheel 1 pc
3. Crystallizing wheel (Cu-Ag alloy) 1 pc
4. Rotary table 1 set
5. Air cylinder 2 pcs
6. Pinch roller 1 set
7. Compression parts holder 1 pc
8. Casting ladle 1 pc
9. Bridge approach holder 1 set
- Molten aluminum flow controller 1 set
11. Cooling device 1 set
12. Water suction gas hood 1 pc
13. Electromagnetic flowmeter 11 pcs
14. Water filter (basket type) 1 pc
15. Cooling water valve switch 8 pcs
II. Straightening machine: 1 set
III. Front hauling: 1 set
1. The base of front hauling 1 set
2. Reduction gearbox 1 set
3. Transmission box 1 set
4. Air cylinder 1 set
IV. Rolling shear 1 set
1. The base of rolling shear 1 set
2. Reduction gearbox 1 set
3. Transmission box 1 set
4. Cutter 4 pcs
V. Guiding carrier roller: 1 set
VI. Induction heater 350Kw
1. Medium-frequency heating furnace electric box 1 set
2. Temperature measure auto control device 1 set
3. Closed type circulating water cooling device 1 set
- Electric cutting saw 1 set
XIII. Continuous rolling mill 450Kw DC motor
1. Large gearbox 1 set
2. Safety coupling 15 pcs
3. Y255 rolling stand 15 pcs
4. Small baseplate of stand 15 pcs
5. Baseplate of large gearbox 1 pc
6. Feeding device 1 set
7. Feeding air cylinder 1 pc
8. Motor coupling 1 set
9. Emulsion branch pipe 1 pc
10. Quick coupling 1 set
11. Spiral bevel gear and pin break indication 1 set
12. Hydraulic safety protection cover 1 pc
IX. Emulsion lubricating parts
1. Belt type vacuum filter unit for emulsion (Hoffman filter) 1 set
2. Emulsion pump 2 pcs
3. Emulsion valve switch 2 pcs
4. Quick coupling 68 pcs
5. Joint 80 pcs
6. Plastic pipe 6” 30m
7. Plastic pipe 4” 40m
8. Valve (1/2”) 80 pcs
9. Valve 2” 1 pc
10. Flange 5” 1 set
11. 40m3 heat exchanger (for continuous rolling mill) 1 set
12. 20m3 heat exchanger (for take-up) 1 set
X. Cooling lubricating parts
1. 4.2m3 oil tank 1 pc
2. Oil pump 2 pcs
3. Oil filter 1 pc
4. Flange 5” 1 set
5. Valve 2” 1 pc
XI. Continuous quenching device 1 set
XII. Dual-basket coiler 1 set
1. Operating deck 1 set
2. Rolling guiding device 1 set
3. Annular rocking beam device 1 set
4. Take-up basket 2 pcs
5. Take-up trolley (with transmission, can take up plum blossom type) 1 set
XIII. Electrical control system
1. DC speed-adjusting control cabinet 1 set
2. AC relay cabinet 1 set
3. Operation cabinet 2 sets
4. DC speed-adjusting motor for continuous rolling mill (450KW) 1 pc
5. Motor for continuous casting machine (4KW) 1 pc
Variable-frequency and variable-speed motor
6. Motor of front hauling (5.5KW) 1 pc
Variable-frequency and variable-speed motor
7. Motor of rolling shear (15KW) 1 pc
8. Beam rocking motor (4KW) 1 pc
9. Motor of back hauling (5.5KW) 1 pc
Variable-frequency and variable-speed motor
10. Motor of take-up basket (1.1KW) 2 pcs
11. Moving motor of take-up trolley (2.2KW) 1 pc
12. Emulsion pump motor for lubrication (22KW) 2 pcs
13. Oil pump motor (5.5KW) 2 pcs
XIV. Others
1. Hole pattern plug gauge 1 set
2. Snap gauge 1 pc
3. Outlet bakelite pipeline 2 sets
4. Oil tank 4.2 m3 1 pc
5. Foundation bolt M27 20 pcs
6. Foundation bolt of casting machine M20 10 pcs
7. Foundation bolt of front hauling M16 6 pcs
8. Foundation bolt of rolling shear M24 8 pcs
