Type UL+Z-1600+255／14铝合金杆连铸连轧设备

Aluminium Rod Continuous Casting and Rolling Machine

一、设备用途Application

本设备采用连铸连轧法工艺生产导电铝合金杆，生产的杆径为Ф9.5mm的合金杆。

The CCR line is the process of continuous casting and rolling technique for producing diameter of Φ9.5mm，alloy rod.

二、简单工艺流程Brief Technological Process

1、工艺流程示意如下 Technical process chart is as follow:

普铝锭→熔化保温炉→轮式整体连铸机→前牵引加辊剪→校直机→感应加热器→连轧机→滑动式无油收杆系统→合金铝杆。

Pure aluminum ingot→ Melting and holding furnace→ Wheel continuous casting mill →Front traction machine & Roller shearer→Straightener→Induction heating apparatus→ Continuous rolling mill→Sliding oil-free coiling system→ Alloy aluminum rod

2、 已配好的熔态铝由保温炉经过流槽，注入轮带式连铸机，连续铸成面积为约2300mm²的梯形锭。用辊剪剪去废锭，将其前端压小，喂入连轧机出杆，经由滑动无油收杆机成捆。

The completed aluminum molten flows through the launder via the holding furnace, pours into the wheel belt type casting mill, which is continuously cast into about 2300mm² trapezoid shape ingot. The scrapped cast bar is cut off by the roller shearer, and the front end is pressed small, then fed into the rolling mill to output the rod, bundled by the oil-free coiler.

三、主要技术参数Main Technical data

导电铝合金杆直径Diameter of the finished rod：      Ф9.5 mm

生产能力Output：                                4.0-5.0 t/h

 各组成部件技术参数Technical parameters for each component

（一）轮式整体连铸机Wheel continuous casting mill

１、结晶轮直径Casting wheel diameter:                 Ф1600 mm

２、结晶轮截面积Cross section of casting wheel:       ≈2300mm²

３、铸锭面积Cross section of cast bar:                 ≈2300mm²

４、浇铸速度Casting speed:                                6.9 - 13.8m/min (500-1000rpm)

５、结晶轮转速Casting wheel speed:                  1.5  - 3.0r/min

６、电动机功率Casting motor power:                  5.5 kw (AC/N=960r/min)

７、冷却水压Cooling water pressure:            0.35-0.6Mpa

８、冷却水量Flow of cooling water:                100t/h (inner 60t/h, external40t/h)

 （二）前牵引加辊剪 Front traction machine & Roller shearer

１、最大剪切力Max. shearing force:          5000kg

２、剪切长度Max. shearing length:            700mm（可调adjustable）

3、辊剪电机Shearing motor power:             15KW AC 970r/min

4、减速机Reducer B6X9 减速比reduction ratio:    71

（三）校直机Straightener

电机功率Motor power          1.5kw/AC；1440r/min i=29

（四）感应加热器Induction heating apparatus

采用三相工频（倍频）加热器，以满足铝锭轧制温度。长度为2.2m，功率约300kw。

Adopt three-phase power frequency heater to meet rolling temperature of aluminum ingot. The length is 2.2m and the power is about 300Kw.

（五）Y型连轧机 Type Y continuous rolling mill

１、型式两辊＋三辊型Type:                   Two&three-roller

２、出杆直径Outlet rod diameter:                              Ф 9.5mm

３、机架数No. of stand:                                      14

４、轧辊名义尺寸Nominal size of roller:               Ф255mm

５、相邻机架传动比Transmission ratio of the neighbor stands:  1 : 1.25

６、终轧速度Finish rolling speed:                          V=7.2m/s（max）

７、轧制中心高Rolling center height:                  902.5mm

８、主电机功率Main motor power:                         400kw (DC)

９、齿轮箱润滑油箱Volume of gear lubrication box:    2 m³

１０、乳化液油池Emulsion tank:                    30-50m³ 

（六）无油淬火收杆机 Oil-free quenching coiler

1、甩杆电机Swing bar motor:                4KW (AC, 1000r/min)

2、甩杆减速机Swing bar reducer:                 WPWRKO-120   

3、收杆最高速度Max. speed of coiling:           6m/s

4、小车行走电机Trolley traveling motor           3KW

5、小车行走减速机Trolley traveling reducer B4X6减速比reduction ratio  43

四、设备组成及结构特点 Composition and structural features

（一）连铸机Continuous casting mill

轮式连铸机由浇煲、结晶轮及传动装置、压紧轮装置、钢带涂油装置、引桥、张紧轮装置、外冷却装置、塞头、剔锭器、钢带等组成，除引桥、张紧轮装置外，其余各部分均安装在机身上。

Wheel type continuous casting mill is made up of ladle, casting wheel, transmission gear device, pinch roller device, steel band oiling unit, bridge approach, tensioning wheel device, external cooling system, chock plug, casting bar-unlock device, steel belt and etc. The bridge approach and the tensioning wheel device are not assembled to the body of casting mill.

熔化的铝液从保温炉经流槽流入上浇口，浮动的塞头控制流入下浇堡的铝液流量，铝液从下浇堡水平浇铸到由结晶轮和封闭钢带所形成的模腔内。结晶轮的截面为Ｍ形，由交流电机经齿轮箱驱动。结晶轮的内侧机身装有内冷却装置，通过压力为0.5Mpa的冷却水，冷却水通过喷嘴喷射到结晶轮的内侧表面上，内冷却共分８区间水冷块，水量可通过截止阀来调节。外冷却装置将冷却水喷射到模腔段的钢带上，从而使铝液逐渐冷却并凝固成温度为480℃－520℃的铝铸锭。外冷却的水量通过截止阀调节。

Molten aluminum flows into upper ladle from the holding furnace through the launder, the inlet flow to the lower ladle controlled by floating chock plug, and horizontally casts into the cavity mould formed by casting wheel and closed steel band. The cross section of casting wheel is shape M, driven by the AC motor gear box. The inner body of casting wheel equipped with the inner cooling device with 0.5 Mpa cooling water transit. The inner cooling device is separated into 8 sections with nozzles to jet cooling water into the inner side of the casting wheel, the flow controlled by the stop valve. The wheel tension is the pneumatic control. The outer cooling device sprays cooling water onto the steel band of cavity mould, flow controlled by stop valve, assuring the gradual cooling of the molten aluminum and cast into the aluminum casting ingot with temperature of 480℃－520℃.

压紧轮装置将钢带紧压在结晶轮上，以防铝金属液体外泄。导轮装置用以调整和改变钢带的走向和模腔的长短，可以在一定范围内调整，钢带的张力通过张紧轮装置进行调节，张紧轮通过气缸恒定的张力，从而使钢带张紧保持一定的张力。为了便于铝铸锭脱模，连铸机还备有钢带涂油装置。由于整个过程是连续进行的，因此可以得到大长度的铸锭。

The pinch roller device adpresses the steel band on casting wheel to avoid the leak of molten aluminum. The guide wheel controls the move direction of the steel band and length of cavity mould, and the tension of the steel band controlled by tensioning wheel device with constant force. To demould the casting bar easily, the casting mill is equipped with steel band oiling unit. As the whole process is continuous, the longer casting bars can be produced.

结晶轮上已凝固了的铸锭由剔锭器剔出，并沿引桥送入辊剪机，剪去废锭及不合格铸锭、沿辊道送入连轧机。

With the casting bar-unlock device of the casting wheel, the clotting casting bar passes the bridge approach into the roller shearer. To shear the scrap bar and unqualified casting bar, the qualified casting bar gets into the continuous rolling mill.

（二）前牵引加辊剪机Front traction machine & Roller shearer

铸坯从浇铸机引桥进入前牵引机，压轮压下将铸坯往前输送经过辊剪进入校直机。辊剪机用于剪切不符合轧制及有毛边铸锭，最大剪切坯料尺寸为2500mm ²以下（温度为450-550℃），最大剪切力5000kg。

The billet enters into the front traction machine from the approach bridge of the casting machine. The casting billet is conveyed forward by the pressing wheel under the pressure and then enters into the straightening machine after shearing. Shearer is used for shearing ingots that do not conform to rolling and have rough edges. The maximum aluminum casting bar is below 2500mm²(temperature 450~550℃), and the maximum shearing force is 5000kg,.

（三）主动校直机Active straightener

五轮式（上二轮下三轮错位安装）、上下翻转结构型式，电动驱动

Five wheel type (two wheels on the top, and three wheels at the bottom, dislocation installation), up and down flip structure, electric drive.

1、主动牵引轮直径Diameter of active traction wheel     3×φ200mm

2、电机功率Motor power              1.5kw/AC；1440r/min i=29

3、压缩空气Compressed air          0.5Mpa

（四）感应加热器Induction heating apparatus

主要技术参数Main technical parameters

（1）  额定功率Rated power  300kW

（2）  感应器电压Inductor voltage  700 V

（3）  被加热工件的材质Material of the heated workpiece 铝合金锭, 铝锭Aluminum or Alloy ingots

（4）  被加热工件的尺寸Size of the workpiece to be heated    2400mm²

（5）  铝锭通过速度Speed of aluminum ingots         8.5--11m/min

（6）  来料温度Material temperature           400-440℃

（7）  升温温度Heating temperature         80-90℃

（8）  生产率Productivity           4.2t/h

（9）  冷却水压力Cooling water pressure  炉体furnace body 0. 2~0.25 MPa，
   （五）连轧机

连轧机由14副机架组成，名义辊径为Ф255，奇数机架为下传动共8副，偶数机架为上传动共7副，左右交替布置。采用园弧——园系统孔型。主传动用400kw直流电机通过弹性联轴节与传动牙箱的主轴连接传递功率。传动牙箱与机架连接处均有安全齿形联轴节，当过截时切断安全肖，以防事故发生。每副机架前后分别装有进出口导位，奇数机架入口导位为滚动式，偶数机架入口导位为滑动式。

 The rolling mill is made up of 14 stands, with nominal diameter Ф255mm, 8 odd stands for lower transmission and 7 even stands for upper transmission, arranged alternately with arch/ round system hole pattern. The elastic coupling and main shaft of gear box connect to transmit power by 400KW DC motor of main transmission gear box.  The safety gear couplings locates in gear box and stands, once over loaded, the safety pin will breaks to avoid the accident. In the front and rear of pair of stands, assembled with inlet guide and outlet guide separately, the inlet guides for the odd No. stands are sliding type, and the inlet guides for the even No. stands are rolling type.

（六）收杆机Coiler

1.绕杆电机功率Coiling motor power转速:     4kw (1000 r/min, frequency control)

2.成圈直径Diameter of coiling:       Φ1900/Φ800×1000mm

3.成圈收杆直径Diameter of coiling rod:      Φ9.5mm，12.5mm

4.最大收线速度Max coiling speed:       7.2m/s

5.收线容量（净重）Capacity of coiling:      1.5-2T (NW)

本机采用成圈收线，由传动部分和收线部分组成。最大收线速7.2m/s，收线速度是由带减速机交流电机变频调速来控制。成圈的直径可从Φ800 mm－Φ1900 mm范围之内调整，成圈高度1000mm。成圈铝杆均匀地落在收线架上。收线转速由带减速器的交流电机变频调速来调节。慢速绕大圈、快速绕小圈，在收杆车框栏内绕成捆。

The machinery adopts coiling system, which is made up of the transmission part and the take-up part. The maximum coiling speed is 6m/s, frequency controlled by AC motor of reducer. The diameter of coiling can be adjusted from range Φ800 mm to Φ1900 mm, with coiling height 1000mm. The coiling aluminum rod is taken up in rotation disk evenly. The coiling speed is regulated by the AC motor with a speed reducer. Slow speed to form big circle, compared with fast speed to form small circle, and bundled into basket.

收杆车台面上有收杆框栏，当框栏收满铝杆后，打开框栏门，卸下铝杆，准备下次收杆。换盘操作为人工切换。

Take-up trolley has basket for coiling. With full basket, open the basket door, to remove the aluminum rod, preparing for the next collection. Change basket operation is manual switching.

（五）润滑冷却系统Lubrication cooling system

 1 轧机乳液系统 一套Emulsion system 1 set

1.1.乳液泵(2台,1台备用）Emulsion pump:    IS100-80-160Q＝90 m3/h, H=36m15 kW  

1.2.工作压力Working pressure:        0.3－0.5Mpa

1.3.过滤器(1台)Filter:                  GLQ-100

乳液润滑系统为双泵系统，乳液分两路经离心泵、过滤器进入装在齿轮箱上面的总管，对各机架的齿轮、轧辊、进出口导卫进行润滑、冷却，最后乳液全部通过底座上的回流槽，经过回流管再回到乳液池。

Emulsion lubrication system is composed with double pumps system. Emulsion flows via centrifugal pump, filter, into the main pipe of top gear box, lubricating and cooling corresponding positions of gears, rollers for stands, inlet and outlet guides. At last, the emulsion back-flow via reflux tank on the base, and backflow connection to the emulsion pool.

2 轧机油润滑系统 一 套 Rolling oil lubrication system 1set

2.1.齿轮泵Gear pump(2台,1台备用):       CY-18/0.36-2  5.5 kW 960r.p.m

2.2工作压力Working pressure:   0.1-0.3Mpa

2.3. 过滤器(1台)Filter:    GLQ-80

2.4.油箱Oil tank:       2m³ 

油箱中的油通过油泵经过滤器来到齿轮箱后的进油总管，分三处进入齿轮箱，然后经过分支油管的喷嘴对齿轮和滚动轴承进行喷溅润滑。回油是从齿轮箱端头下侧经回油管到油箱。

Lubrication oil of oil tank flows via filter by oil pump, to the main oil inlet pipe at the rear of gear box. Lubrication oil is transported to gear box in three ways through nozzle of branch oil pipe to lubricate gears and bearings respectively. The oil backflows to the oil tank through pipelines at the bottom of the gear box, which can be used circularly.

五、电气概况 Overview of electrical system

电气系统由三相四线380V, 50Hz低压网络供电，设备总功率约为600kw,其中主电机400kw，是用西门子全数装置控制，余下辅机均控制柜供电.

The electrical system is power supplied by three-phase four-wire 380V, 50Hz, low voltage. The total power of the machinery is about 600kw, and the main motor power is 400kw, which is controlled by Siemens full digital device. The other auxiliaries are power supplied by rolling mill control desk.

REAMARK: All photos are for your information, not the final delivery reference.