Upward Casting Machine

UpwardCasting Machine

Working Process
The upward casting machinecomes with a power frequency induction furnace which functions to melt theelectrolytic copper into liquids. In order to prevent oxidation, the copperliquid is covered with wood charcoal or coal gas to separate from the air. Theheat preservation furnace serves to control the liquid temperature at 1150℃±10℃,and then the copper liquid becomes into copper rods continuously via thecrystallizer. Finally, through processing by other auxiliary equipment of theupward casting machine, the copper rods become into end products.

Equipment Composition
The upward casting machine is composed of power frequency inductionfurnace, casting machine, guide wheel frame, position-limiting device,double-head loop formation and rewinding device, water cooling system,electrical control system and material feeding system and temperature-measuringsystem, etc.

1. Power frequency induction furnace of the upward casting machine
It is mainly composed of furnace body, frame andinductor.
The housing is of steel structure and inside of the furnace is built up usingrefractory brick and quartz sand. The frame functions to support the wholefurnace, and is fixed onto the foundation using foundation bolt. The inductoris composed of winding, water jacket, iron core, and molten channel primarily.The primary coil comes with cooling system and the voltage is adjustablebetween 90V to 420V. The secondary coil is made up of short circuited moltenchannel. After power on, inside the molten channel there is a largecurrent and low voltage due to electromagnetic induction. Thus, theelectrolytic copper is molten. Both the water jacket and windings are watercooled, and the cooling water is recyclable. 

2. Continuous casting machine
Continuous casting machine is the key component of the upward casting machine.It is mainly composed of traction unit, liquid level control system andcrystallizer.
The traction unit consists of AC servo motor and traction roller wheel. It canachieve intermittent movements at a frequency of 0-600 times per minute andeach traction unit can drive 5 pull rollers to pull 5 pieces of casting rod.Through changing the crystallizer, both φ20mm and φ16mm cast copper rods can bemanufactured.
The liquid level control system functions to make cure thecrystallizer is inserted into the copper liquid at a stable depth, so asto ensure continuous production.
The crystallizer allows the copper liquid to cool down quickly to become intosolid state. Each crystallizer can be independently controlled and exchangedwithout influence to the other ones.

3. Guide wheel frame
The guide wheel frame is positioned at the top ofcontinuous casting machine, and is mainly composed of a platform, frame,vertical guide wheels and rotary drum. It functions to send cast copper rodssmoothly to the loop formation and rewinding unit.

4. Position-limiting device
The device is positioned between the guide wheel frameand the loop formation and rewinding unit. It is made up of 6 sets of 24V lowvoltage upper and lower limit stops. It serves to control the speed of loopformation and rewinding unit through the contact between the copper rods andthe limit stops.

5. Loop formation and rewinding unit
This unit is mainly composed of traction roller wheel,loop formation device and rewinding device. Each unit comes with two electricalmotors to drive two loop formation device separately,thus looping two copper rods simultaneously. The curvature is adjustableautomatically.

6. Water cooling system
This is an independent cycling water supplying systemof the upward continuous casting machine. It serves to supply cool water at 0.2~0.4Mpa to cool crystallizers, water jacket, andwindings. The water cooling system is made up of a 120m3 water pool,water pump, pipelines and cooling tower, etc. It can make sure the feedingwater temperature is maintained at 20~30°C and the flow is 30m3/h approximately.

7. Electrical control system
The electrical control system is composed of powersupply system and control system primarily. The power supply system functionsto supply electrical power to each inductor via several electric distribution box. The control system functions to guarantee the smoothand reliable operation of the entire upward casting machine.

8. Material feeding system
The system functions to feed electrolytic coppermaterials continuously, thus ensuring the continuous operation of the upwardcasting machine.

9. Temperature-measuring system
The system mainly consists of two parts: copper liquidtemperature and cooling water temperature measuring systems. The measuredtemperatures are displayed through the thermometer.

Technical Specification of Copper RodsManufactured by the Casting Machine
1. Density: ~8.9g/cm3
2. Tensile strength: > 170N/mm2
3. Elongation: > 35%
4. Conductivity: ≥ 100%IACS（φ2m2n flexible wire ）
5. Oxygen content ≤10ppm

Technical Specifications of UpwardCasting Machine
1. The upward casting machine canbe used for producing 5000 tons of copper rods annually
2. Furnace structure: three-furnace combination (2 melting furnaces and 1 heatpreservation furnace)
3. Casting rod quantity: 10
4. Casting rod diameter: φ20 mmor φ16 mm
5. Upward casting speed: 0~1200 mm/min
6. Annual working hours: 8,000 hours
7. Liquid level control tolerance: ±2 mm
8. Loop formation: φ700 mm×φ1500 mm
9. Copper melting speed: 650㎏/h
10. Electricity consumption for copper melting: 350kwh/ton

Configuration Details
1. Continuous casting machine
Traction motor: YASKAWA AC servo motor, 3KW
Liquid level control AC motor: AC2.2KW   2900rpm

2. Double-head loop formation and rewinding device
AC motor: 1.5KW/960

3. Electrical control system of the upward continuous casting machine iscomposed of:
Siemens AC contactor,
Siemens low power air switch,
Big power air switch from Shanghai Huatong Swithgear Company based in China,
Mitsubishi PLC and touch screen,
SHTC brand fuse,
Shizuki capacitor acquired from WuxiKangpate, and more.
In addition, the winding, water jacket, iron core and voltage regulator arenon-standard and are acquired from professional manufacturers in China.

Thanks for your interest in our upward casting machine. In order to ensure ourcustomers find the product they require, we offer hydraulic automatic drawingbench machinery, automatic on-line cutting machine, and continuous extrusionmachine, etc. At Yajue, it is our goal to provide highquality, affordable large scale electrical equipment for customers all over theglobe. To achieve this, we acquire quality raw materials from local suppliers,utilize advanced equipment, and conduct strict quality inspections of allfinished products. These factors enable us to offer high quality products atcompetitive prices. For further inquires, you are welcomed to contact us at Yajue, aprofessional manufacture and supplier of upward casting machine in China.