Auto Ingot Casting Machine

A V e n t u r e o f C a p t . A n i l K . V e r m a

The matter was conceived and written by Capt. Anil K. Verma.

Auto Ingot Casting Machine

Technical Specifications of Auto Ingot Casting Machine This Ingot Casting Conveyor will operate in conjunction with a suitable capacity of refining pots. Your require ingot casting machine to produce 25~26 kg lead ingots with a Production capacity of 10 tons per hour.

The final system will be composed of the following machines and equipments 1. Flow Control Box (Tundish) is mounted adjacent to the distributor wheel. It consists of a cast iron box with a replaceable nozzle. A manually adjusted stopper controls flow from the holding control box to the wheel. Control Box can hold 250 to 300 kg molten lead. There will be pre-heating burners mounted on the Control box to maintained the temperature of molten lead. At the end of casting cycle, operator has to closed the nozzle with control pin, otherwise molten metal will be solidify in the nozzle. Nozzles can be clean & replace.

2. Tilting Launder: - The launder that feeds controlled molten lead to the wheel. It is a M.S. fabrication that is designed to give turbulence free flow to the molten metal. This launder is pivoted so that the metal will be directed away from the casting machine into a dump mould by manually. At the end of the cast the tilting of the launder facilitates it's cleaning.

3. Distributor Wheel: Ÿ The distributor wheel is made by Cast Iron and used for distribute the metal into the moulds. Ÿ The wheel has single outlet spouts that dip into each mould. Ÿ The wheel is mounted on upper sprocket directly. Ÿ The metal is poured via a launder direct into the centre of the wheel. Ÿ Distributor wheel is made as per our design. Ÿ Distributor wheel have a pre-heating burners. Distributor temperature should be 60 to 70 degree C (It should be dry) before cast the ingots.

4. Ingot Casting Conveyor: - This is inclined style conveyor, to carry 80 moulds on a double chain pitch of 130 mm; sprocket centers of 4,445 mm and an overall length of 5 meters.

The conveyor will be complete when assembled with:

4.1. Ingot Mould: - A set of Cast Iron moulds. Each to produce a 25~28 kg lead ingot to our standard design. There are four holes on ingot moulds to bolt on chain attachment.

4.2. Conveyor Chain: - The moulds are mounted on a proprietary conveyor chain with a pitch of 130mm. The chain has a breaking strain of 134kN. The chain has K2 attachments, one side of every pitch. The conveyor chain is manufactured for special grade steels (Links MOC is En-8, Roller MOC is 20MnCr5, Pin MOC is En-8 with hardened, ground & blackodised.)

4.3. Idler- end Assembly: Bearings are heavy duty bearings selected according to the duty required. Drive and Idler shafts are manufactured from EN8 Bright drawn steel. It's hardened, ground & blackodised. Sprockets 130mm pitch are C.N.C. profiled from En-8 with hardened & blackodised. All bearings are NTN Make.

4.4. Drive end Assembly: Drive motor assembly with a final drive shaft is mounted directly on the casting machine drive. Ÿ The drive used will be a PBL make. Ÿ Variable speed control is achieved with a frequency inverter (VFD) Ÿ Delta / Mitsubishi/ABB Or Equivalent VFD is considered. Ÿ Pot have a manual operated valve so molten lead flow will be some times high OR sometimes low. In this connection we have to control the machine speed to get the suitable size & weight ingots.

Auto Ingot Casting Machine

4.5. Ingot Knockout Arrangement: Two arms are pneumatically actuated to strike each mould as it passes round the drive haft of the conveyor. This arrangement is used to release the ingot from the moulds easily. All pneumatic items will be Festo/SMC Make.

4.6. Ingot Retaining Mechanism: Ÿ Curved arms hold the ingots in the moulds as they pass round the drive shaft. When the moulds are inverted the arms allow the ingots to escape from the moulds. Ÿ Robust profiled steel plates are pivoted from the frame to enable the frame to move away in the event of metal on top of the moulds. Ÿ The curved profile closely follows the form of the moulds as they pass round the drive shaft.

5. Mould Cooling Arrangement :

Ÿ A manifold of water nozzles produces a very fine atomized spray. Ÿ These high pressure sprays propel the water hard against backs of the full moulds and the returning hot moulds. Ÿ The cooling effect of the high pressure fine mist water spray gives maximum heat transfer. By turning most of the water to steam, consumption is reduced and water return is minimized. Ÿ Spray nozzles consist of Stainless Steel 304. All water piping will be galvanized pipes.

6. Pre-heating Arrangement: L.P.G. Burners are provided to dry and preheat the moulds and the distributor wheel. Total seven nos. burners are provided. Two burners for ingot mould, Two burners for distributor wheel, Two burners for control box, one burner is flexible for ignite all the burners. All burners consist of cast iron. Copper piping, Flow regulators, Non- return valves are considered. Main header line will be made by steel.

7. Control System:

Ÿ The ingot casting machine can be operated automatically from a central control panel whose location will be specified in the layout drawing. Ÿ There will be suitable Variable Frequency Drive that control speed of the ingot casting conveyor. Ÿ Provision for emergency stop: There will be an emergency stop button.

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