Laboratory Casting Plant based on semicontinuous casting unit for manufacturing of rolling ingots and extrusion billets
The unit was designed and manufactured for a laboratory based at the Siberian Federal University for the development of processes and technology of semi-continuous casting of rolling ingots and extrusion billets. Features of the unit are the ability to melt a solid charge and prepare melts of given chemical composition in a rotary resistance stirrer and simulation of real production conditions.
Task:
- Автоматизируемые процессы/системы: система подачи воды в кристаллизатор литейной машины, механизм подъема/опускания литейной платформы, а также системы нагрева и поворота наклонного миксера
- Manufacturing of a casting unit on the basis of the UPNL casting machine, two crucible rotary furnaces PPI-0.16 and a rotary resistance holder
- The work included automation of the processes in accordance with the documentation developed by our specialists
- Automated processes/systems: system of water supply to the mold of the casting machine, mechanism of casting platform raising/lowering, and heating and turning systems of the tilting holder
Customer:
FSAEI HE Siberian State University, Krasnoyarsk
Project Year:
2018
Problems prior to implementation:
- Crucible furnaces PPI-0,16 do not function
- Holder of small-capacity and insufficient functions
- Outdated casting platform control system
- Lack of automated water supply to the caisson
- Lack of a single working platform and launders
- Localized control systems without integration into the main PLC
Key features:
Resistance holder:
- Temperature of heaters 800-900°С
- Capacity of molten aluminum bath 100 kg.
- Maximum angle of holder rotation 29°С
- Separate control of the heating power of each of three zones of silicon carbide heaters
- Electromechanical lift drive
Control cabinet:
- Total power 31 kW
- PID controller
- Thyristor power control
- Cabinet 1200х600х300 mm
- Degree of protection – IP65
Launder:
- Refractory Concrete Cartridges
- 95 mm deep trays
- Four sliding valves
Jib crane:
- Load capacity 250 kg
- length of jib up to 3 m
- The manual rotary actuator of the jib
- Lifting speed – up to 8 m/min
Ventilation:
- Volume of vented gases up to 2700 m3/hour
- Material of the duct – galvanized steel
Result:
Reduction of ingot crop ends to three times
Heat losses of the melt during start-up decreased down to 0.5°C/m
Fast warming-up of concrete cartridges within 1.5–2 hours
Flexible heating control
Easy maintenance and good maintainability
