Aluminum Rod Continuous Casting and Rolling Line

QUOTS VARIE BASED ON THE REQUIREMENTS
OF DIFFERENT COMPONENTS

ALUMINUM ROD CONTINUOUS CASTING AND ROLLING LINE
TYPE LGZ-1500/Y

1. Application and Composition
By means of continuous casting and rolling, this line is used to produce conductive aluminum rod in diameterΦ9.5mm and Φ12mm, mainly consisting of:
1.1 Two-wheel type casting machine (including cooling system)
1.2 Hydraulic shearer and hoist device
1.3 Continuous rolling machine (Including active feeding device)
1.4 Emulsion supply system for the rolling machine (including filter system)
1.5 Lubricating oil supply system for the gear box of rolling machine (including filter system)
1.6 Guide pipes, rod coiler
1.7 Electrical control system

2. Process Flow
Normal aluminum ingot→ melting furnace→ holding furnace →launder→ continuous casting machine→ guide pipe for outlet pipe(including operation ladder)→ rear haul-off device &platform→ coiler to attain plum-shaped outlet al rod

3. Main Technical Data
3.1 Diameter of aluminum rod:                            φ9.5±0.5 mm; φ12±0.5 mm
3.2 Output capacity:                         4.2 t/h
3.3 Coiled rod weight                     2~2.5t
3.4 Overall size                                38mx8mx8m (excluding furnace)
3.5 Total weight:                               approx. 72t (excluding furnace)
3.6 Total installed power:               400kw (excluding furnace)
3.7 Noise:                          ≤80Db
3.8 Work power                     AC380V 50Hz
 
4. Specifications of Components
4.1 Two-wheel Continuous Casting Machine
4.1.1 Diameter of crystallizing wheel:      φ1500 mm
4.1.2 Cross sectional area of cast bar:   ~2440 mm2
4.1.3 Motor power for casting:                   3kw (AC Frequency converter)
4.1.4 Cooling water consumption:     100 m3 /h(soft water)
4.1.5 AC motor for pump of cooling water recycling: 22Kw, 2 sets (one for stand-by)
Continuous casting machine mainly Consists of crystallizing wheel, compressing wheel , tensioning wheel, guide wheel, ladle, cooling device, dust remover, bar catcher, guide bridge, water saving device and pneumatic control system(external water supply system and soft water treating system are provided by users).
The casting machine is of the two-wheel structure, is sprayed from three sides and controlled by separate ways 

4.2 Single-track Oil Hydraulic Shearer
  Mainly consists of single-track crane, oil pressure shearing device and oil line system, the max. shearing force is 15000kgf, the traveling distance is 65mm.

4.3 Continuous Rolling Machine (Including motorized feeding device)
4.3.1 Main motor:                             DC250 kW
4.3.2 Final rolling speed              6.2 m/s
4.3.2 Diameter of outlet aluminum rod:  φ9.5mm; φ12mm
4.3.4 Center height of rolling:                    902.5 mm
4.3.5 No. of Three rollers stand:               15 stands
4.3.6 Stands for stand-by use:                15 stands (same to the ones in the rolling machine)
4.3.7 Nominal diameter of roller:             φ225 mm
Rolling machine adopts the 15- pass rolling system with the active feeding system; gearbox and seat are cast by cast iron accurately as a whole piece; Rolling unit consists of 15 pairs of 255Y type stands, which is designed into upper and lower transmission alternately. when the overload caused by the accidents happens during rolling process, the shearing pin in the safety coupling will be cut off, which can well protect the transmission gear and shafts.

4.4 Emulsion system
4.4.1 Emulsion pumps:                                         100m3 /h 22KW, 2 sets (one for stand-by)
4.4.2 Filter:                                                    WQ-100 1.1kw motor, 1 set
4.4.3 Plate type heat exchanger:      50m2, 1 set
4.4.5 Emulsion tank:                       150 m3 (Prepared by user) 

4.5 Lubrication system for rolling machine
4.5.1 Gear Pump:                   5.5kw, 1set
4.5.2 Filter:                                        WQ-80, 1.1kw, 1 set
4.5.3 Oil tank:                       V=5 m3

4.6 Guide pipe and support for rod delivery

4.7 Two-position coiler
4.7.1 Coiling diameter:                                                       φ2300 mm
4.7.2 Star-type coiling trolley:
4.7.3 Coling weight:                                                            2~2.5 tons

4.8 Down coiler
The coiler mainly consists of operation platform, clamping and delivery device, guide bridge, ring-shape wire swinging device, trolley, etc.
4.8.1 Motor for rear haul-off:         AC 7.5Kw (frequency converter)
4.8.2 Diameter of coil:               2300mm
4.8.3 Motor for rod winding:          4kW/AC (Frequency converter)
4.8.4 Coiler trolley:
The basket can rotate so that it is available for the plum shaped down coiling. In addition it is mounted the rod accumulator while changing reels
4.8.5 Motor for basket rotating:                 2.2Kw/Ac (Frequency converter)
4.8.6 Rod coiling weight              2~2.5T

4.9. Electric Control System
  The whole rolling system adopts PLC control which is reliable and easy to operate. The instruction of main allocated device is provided.
4.9.1PLC:                                                      from Siemens  S7-1200/200
4.9.2 Controller for DC motor:         SSD 591+,Eurotherm, U.K.
4.9.3 Controller for frequency change:  YASKAWA,JAPAN
4.9.4 Usual units with low voltage:          from the units of Siemens (within 63A)