一、設備用途Application 本設備采用連鑄連軋法工藝生產(chǎn)導電鋁合金桿，生產(chǎn)的桿徑為Ф9.5mm的合金桿。 The CCR line is the process of continuous casting and rolling technique for producing diameter of Φ9.5mm，alloy rod. 二、簡(jiǎn)單工藝流程Brief Technological Process 1、工藝流程示意如下 Technical process chart is as follow: 普鋁錠→熔化保溫爐→輪式整體連鑄機→前牽引加輥剪→校直機→感應加熱器→連軋機→滑動(dòng)式無(wú)油收桿系統→合金鋁桿。 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、 已配好的熔態(tài)鋁由保溫爐經(jīng)過(guò)流槽，注入輪帶式連鑄機，連續鑄成面積為約2300mm2的梯形錠。用輥剪剪去廢錠，將其前端壓小，喂入連軋機出桿，經(jīng)由滑動(dòng)無(wú)油收桿機成捆。 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、主要技術(shù)參數Main Technical data 導電鋁合金桿直徑Diameter of the finished rod： Ф9.5mm 生產(chǎn)能力Output： 4.0-5.0 t/h
Type UL+Z-1600+255／14鋁合金桿連鑄連軋設備
Aluminium Rod Continuous Casting and Rolling Machine
一、設備用途Application
本設備采用連鑄連軋法工藝生產(chǎn)導電鋁合金桿，生產(chǎn)的桿徑為Ф9.5mm的合金桿。
The CCR line is the process of continuous casting and rolling technique for producing diameter of Φ9.5mm，alloy rod.
二、簡(jiǎn)單工藝流程Brief Technological Process
1、工藝流程示意如下 Technical process chart is as follow:
普鋁錠→熔化保溫爐→輪式整體連鑄機→前牽引加輥剪→校直機→感應加熱器→連軋機→滑動(dòng)式無(wú)油收桿系統→合金鋁桿。
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、 已配好的熔態(tài)鋁由保溫爐經(jīng)過(guò)流槽，注入輪帶式連鑄機，連續鑄成面積為約2300mm2的梯形錠。用輥剪剪去廢錠，將其前端壓小，喂入連軋機出桿，經(jīng)由滑動(dòng)無(wú)油收桿機成捆。
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、主要技術(shù)參數Main Technical data
導電鋁合金桿直徑Diameter of the finished rod： Ф9.5 mm
生產(chǎn)能力Output： 4.0-5.0 t/h
各組成部件技術(shù)參數Technical parameters for each component
（一）輪式整體連鑄機Wheel continuous casting mill
１、結晶輪直徑Casting wheel diameter: Ф1600 mm
２、結晶輪截面積Cross section of casting wheel: ≈2300mm2
３、鑄錠面積Cross section of cast bar: ≈2300mm2
４、澆鑄速度Casting speed: 6.9 - 13.8m/min (500-1000rpm)
５、結晶輪轉速Casting wheel speed: 1.5 - 3.0r/min
６、電動(dòng)機功率Casting motor power: 5.5 kw (AC/N=960r/min)
７、冷卻水壓Cooling water pressure: 0.35-0.6Mpa
８、冷卻水量Flow of cooling water: 100t/h (inner 60t/h, external40t/h)
（二）前牽引加輥剪 Front traction machine & Roller shearer
１、最大剪切力Max. shearing force: 5000kg
２、剪切長(cháng)度Max. shearing length: 700mm（可調adjustable）
3、輥剪電機Shearing motor power: 15KW AC 970r/min
4、減速機Reducer B6X9 減速比reduction ratio: 71
（三）校直機Straightener
電機功率Motor power 1.5kw/AC；1440r/min i=29
（四）感應加熱器Induction heating apparatus
采用三相工頻（倍頻）加熱器，以滿(mǎn)足鋁錠軋制溫度。長(cháng)度為2.2m，功率約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型連軋機 Type Y continuous rolling mill
１、型式兩輥＋三輥型Type: Two&three-roller
２、出桿直徑Outlet rod diameter: Ф 9.5mm
３、機架數No. of stand: 14
４、軋輥名義尺寸Nominal size of roller: Ф255mm
５、相鄰機架傳動(dòng)比Transmission ratio of the neighbor stands: 1 : 1.25
６、終軋速度Finish rolling speed: V=7.2m/s（max）
７、軋制中心高Rolling center height: 902.5mm
８、主電機功率Main motor power: 400kw (DC)
９、齒輪箱潤滑油箱Volume of gear lubrication box: 2 m3
１０、乳化液油池Emulsion tank: 30-50m3
（六）無(wú)油淬火收桿機 Oil-free quenching coiler
1、甩桿電機Swing bar motor: 4KW (AC, 1000r/min)
2、甩桿減速機Swing bar reducer: WPWRKO-120
3、收桿最高速度Max. speed of coiling: 6m/s
4、小車(chē)行走電機Trolley traveling motor 3KW
5、小車(chē)行走減速機Trolley traveling reducer B4X6減速比reduction ratio 43
四、設備組成及結構特點(diǎn) Composition and structural features
（一）連鑄機Continuous casting mill
輪式連鑄機由澆煲、結晶輪及傳動(dòng)裝置、壓緊輪裝置、鋼帶涂油裝置、引橋、張緊輪裝置、外冷卻裝置、塞頭、剔錠器、鋼帶等組成，除引橋、張緊輪裝置外，其余各部分均安裝在機身上。
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.
熔化的鋁液從保溫爐經(jīng)流槽流入上澆口，浮動(dòng)的塞頭控制流入下澆堡的鋁液流量，鋁液從下澆堡水平澆鑄到由結晶輪和封閉鋼帶所形成的模腔內。結晶輪的截面為Ｍ形，由交流電機經(jīng)齒輪箱驅動(dòng)。結晶輪的內側機身裝有內冷卻裝置，通過(guò)壓力為0.5Mpa的冷卻水，冷卻水通過(guò)噴嘴噴射到結晶輪的內側表面上，內冷卻共分８區間水冷塊，水量可通過(guò)截止閥來(lái)調節。外冷卻裝置將冷卻水噴射到模腔段的鋼帶上，從而使鋁液逐漸冷卻并凝固成溫度為480℃－520℃的鋁鑄錠。外冷卻的水量通過(guò)截止閥調節。
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℃.
壓緊輪裝置將鋼帶緊壓在結晶輪上，以防鋁金屬液體外泄。導輪裝置用以調整和改變鋼帶的走向和模腔的長(cháng)短，可以在一定范圍內調整，鋼帶的張力通過(guò)張緊輪裝置進(jìn)行調節，張緊輪通過(guò)氣缸恒定的張力，從而使鋼帶張緊保持一定的張力。為了便于鋁鑄錠脫模，連鑄機還備有鋼帶涂油裝置。由于整個(gè)過(guò)程是連續進(jìn)行的，因此可以得到大長(cháng)度的鑄錠。
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.
結晶輪上已凝固了的鑄錠由剔錠器剔出，并沿引橋送入輥剪機，剪去廢錠及不合格鑄錠、沿輥道送入連軋機。
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）前牽引加輥剪機Front traction machine & Roller shearer
鑄坯從澆鑄機引橋進(jìn)入前牽引機，壓輪壓下將鑄坯往前輸送經(jīng)過(guò)輥剪進(jìn)入校直機。輥剪機用于剪切不符合軋制及有毛邊鑄錠，最大剪切坯料尺寸為2500mm 2以下（溫度為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）主動(dòng)校直機Active straightener
五輪式（上二輪下三輪錯位安裝）、上下翻轉結構型式，電動(dòng)驅動(dòng)
Five wheel type (two wheels on the top, and three wheels at the bottom, dislocation installation), up and down flip structure, electric drive.
1、主動(dòng)牽引輪直徑Diameter of active traction wheel 3×φ200mm
2、電機功率Motor power 1.5kw/AC；1440r/min i=29
3、壓縮空氣Compressed air 0.5Mpa
（四）感應加熱器Induction heating apparatus
主要技術(shù)參數Main technical parameters
（1） 額定功率Rated power 300kW
（2） 感應器電壓Inductor voltage 700 V
（3） 被加熱工件的材質(zhì)Material of the heated workpiece 鋁合金錠, 鋁錠Aluminum or Alloy ingots
（4） 被加熱工件的尺寸Size of the workpiece to be heated 2400mm2
（5） 鋁錠通過(guò)速度Speed of aluminum ingots 8.5--11m/min
（6） 來(lái)料溫度Material temperature 400-440℃
（7） 升溫溫度Heating temperature 80-90℃
（8） 生產(chǎn)率Productivity 4.2t/h
（9） 冷卻水壓力Cooling water pressure 爐體furnace body 0. 2~0.25 MPa，
（五）連軋機
連軋機由14副機架組成，名義輥徑為Ф255，奇數機架為下傳動(dòng)共8副，偶數機架為上傳動(dòng)共7副，左右交替布置。采用園弧——園系統孔型。主傳動(dòng)用400kw直流電機通過(guò)彈性聯(lián)軸節與傳動(dòng)牙箱的主軸連接傳遞功率。傳動(dòng)牙箱與機架連接處均有安全齒形聯(lián)軸節，當過(guò)截時(shí)切斷安全肖，以防事故發(fā)生。每副機架前后分別裝有進(jìn)出口導位，奇數機架入口導位為滾動(dòng)式，偶數機架入口導位為滑動(dòng)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）收桿機Coiler
1.繞桿電機功率Coiling motor power轉速: 4kw (1000 r/min, frequency control)
2.成圈直徑Diameter of coiling: Φ1900/Φ800×1000mm
3.成圈收桿直徑Diameter of coiling rod: Φ9.5mm，12.5mm
4.最大收線(xiàn)速度Max coiling speed: 7.2m/s
5.收線(xiàn)容量（凈重）Capacity of coiling: 1.5-2T (NW)
本機采用成圈收線(xiàn)，由傳動(dòng)部分和收線(xiàn)部分組成。最大收線(xiàn)速7.2m/s，收線(xiàn)速度是由帶減速機交流電機變頻調速來(lái)控制。成圈的直徑可從Φ800 mm－Φ1900 mm范圍之內調整，成圈高度1000mm。成圈鋁桿均勻地落在收線(xiàn)架上。收線(xiàn)轉速由帶減速器的交流電機變頻調速來(lái)調節。慢速繞大圈、快速繞小圈，在收桿車(chē)框欄內繞成捆。
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.
收桿車(chē)臺面上有收桿框欄，當框欄收滿(mǎn)鋁桿后，打開(kāi)框欄門(mén)，卸下鋁桿，準備下次收桿。換盤(pán)操作為人工切換。
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）潤滑冷卻系統Lubrication cooling system
1 軋機乳液系統 一套Emulsion system 1 set
1.1.乳液泵(2臺,1臺備用）Emulsion pump: IS100-80-160Q＝90 m3/h, H=36m15 kW
1.2.工作壓力Working pressure: 0.3－0.5Mpa
1.3.過(guò)濾器(1臺)Filter: GLQ-100
乳液潤滑系統為雙泵系統，乳液分兩路經(jīng)離心泵、過(guò)濾器進(jìn)入裝在齒輪箱上面的總管，對各機架的齒輪、軋輥、進(jìn)出口導衛進(jìn)行潤滑、冷卻，最后乳液全部通過(guò)底座上的回流槽，經(jīng)過(guò)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 軋機油潤滑系統 一 套 Rolling oil lubrication system 1set
2.1.齒輪泵Gear pump(2臺,1臺備用): CY-18/0.36-2 5.5 kW 960r.p.m
2.2工作壓力Working pressure: 0.1-0.3Mpa
2.3. 過(guò)濾器(1臺)Filter: GLQ-80
2.4.油箱Oil tank: 2m3
油箱中的油通過(guò)油泵經(jīng)過(guò)濾器來(lái)到齒輪箱后的進(jìn)油總管，分三處進(jìn)入齒輪箱，然后經(jīng)過(guò)分支油管的噴嘴對齒輪和滾動(dòng)軸承進(jìn)行噴濺潤滑?；赜褪菑凝X輪箱端頭下側經(jīng)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、電氣概況 Overview of electrical system
電氣系統由三相四線(xiàn)380V, 50Hz低壓網(wǎng)絡(luò )供電，設備總功率約為600kw,其中主電機400kw，是用西門(mén)子全數裝置控制，余下輔機均控制柜供電.
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.
