Frequency Control Hot Top Casting Machine 5 tons - 60 tons Continuous Casting Machine For Profile

Hop top billet casting machine for window and door profile manufacturing

Process Description

Casting process starts after refining and holding of aluminium alloy’s molten metal.

Poured out from the furnace sprout, the molten metal flows through launder, filtered by ceramic foam filter (CFF), and then enters the casting table where the casting moulds are fixed on. When the casting is finished, the casting table is 90° tilted with the moulds, and then the billets can be lifted up by suspending tools.

Technical Parameters

Casting machine is trackless steel wire rope type; It adopts frequency control, adjusting speed between 60～850mm/min.It can move up / down either inching or automatically. Digital displays the speed, casting length, inlet cooling water temperature and molten metal temperature, there is audible alarm when reaching the end of casting and safety stop before bottom casting table coming up to position.

It adopts single-coil, four-steel-wire-rope; the winch is equipped with manual descending device & spring aid starting device. Electrics for controlling for the winch & hydraulic system are set in an electric control cabinet.

Casting pit frame is of 25# channel steel and steel sheet. Four main pulleys of the winch are installed at four inner corners of the casting pit frame, and tilting pedestal & cylinders are installed on its outer rims. Upper plate of the top casting table is 25mm thick, bottom one is 14mm, which is welded with steel plates of 12mm thick.

Hydraulic flat-form laterally turns 90°. Tilting mechanism is operated by hydraulic system. Hydraulic cylinders and pumps are made in China, and main hydraulic valves are made by Yuken. Rotary joint & connector of the water inlet are installed beside the cylinders.

Casting pit dimension: to be determined.

Billet casting length: 6300mm, casting capacity per batch: 10t/ 15t

φ178 ± 1mm × 24pcs (10.15t)

φ178 ± 1mm × 36pcs (15.23t)

Material of launder lining, filter box lining, thimble & distribution board is “Zhongnai No. 1”. Outer side of launder and filter box are made of steel; filter plate size is 20 inches.

Parameters

FAQ 

1. What are the key points of daily inspection?

Aluminum liquid temperature/level, flow channel/filtration, crystallizer (water temperature/pressure/flow rate), casting speed/traction, and surface quality of cast rod.

2. What is the regular maintenance cycle?
Daily: Clean the slag from the furnace mouth/flow channel; inspect the burner, ignition system, and seals.
Weekly: verify thermocouples/temperature control instruments; clean the scale in the water gap of the crystallizer; check the integrity of the filter plate.
Monthly: Conduct a comprehensive inspection of the lining thickness/cracks; calibrate the casting speed and traction synchronization; replace aged sealing rings/gaskets.
Every year: overhaul the furnace body (repair/reline the furnace lining); conduct a comprehensive inspection and maintenance of the casting machinery and electronic control system.
3. Safety precautions?
High temperature protection: Wear high temperature resistant clothing, protective face masks, and heat-insulating gloves to avoid burns.
Explosion protection: Leakage is strictly prohibited in gas furnaces, and regular leak detection is required; moist materials are prohibited inside the furnace to prevent explosions caused by water encountering aluminum liquid.
Emergency response: Equip with dry powder fire extinguishers and dry sand.
4. The reason of the dimensions of the cast rods out of tolerance (ellipsoidal, bent, uneven diameter)?
Reasons: deformation/wear of the crystallizer, uneven cooling water, unstable casting speed, asynchronous traction machine, uneven base.
Solution:
Crystallizer: Regularly inspect the roundness/wear of the inner wall, and replace it promptly if it exceeds the tolerance; clean the scale from the water gaps to ensure uniform cooling.
Speed / Traction: Stabilize the casting speed, calibrate the synchronicity of the traction machine; ensure the base is level and reduce vibration.
5. The reason of cast rod porosity / shrinkage cavity (internal voids, poor density)?
Reasons: Excessively high pouring temperature, too fast casting speed, insufficient cooling, poor shrinkage compensation, and a wide solidification range of the alloy.
Solution:
Temperature / Speed: Reduce the pouring temperature, appropriately decrease the casting speed, and extend the solidification time.
Cooling: Enhance the cooling intensity of the crystallizer to ensure sufficient secondary cooling; optimize the water flow distribution in the crystallizer.
Shrinkage compensation: Design the runner reasonably, strengthen the riser for shrinkage compensation, and reduce shrinkage cavities.