Aluminum Rod Continuous Casting and Rolling Machine (CCR Line)

Specially for producing aluminum alloys (4XXX Al-Si, 5154 Al-Mg, 6XXX Al-Mg-Si, 8XXX Al-other alloy) rod of diameter ø9.5mm for electrical wire. And also it can produce electrical aluminum (1XXX pure aluminum, AL>99%) rod of diameter ø9.5mm, ø12mm, ø15mm.

2. Equipment composition

It is composed of casting machine, ingot tractor, scrolling shear, straightener, frequency doubling heater(producing aluminum alloy), continuous rolling mill, oil lubrication systems, emulsion lubricating and cooling system, emulsion heater(producing 4XXX Al-Si and5154 Al-Mg), curve type oil-free automatic rod coiling take up device, electric control system, etc.

3. Brief process flow

Aluminum (Alloy) ingot → melting →heat preservation → casting →ingot tractor→ scrolling shear→ straightening → heating on line→ rolling →curve type oil-free automatic rod coiling take up device or quenching and coiling device→ aluminum (alloy) rod

4. Main technical data

1. Crystallizing wheel dia.:        ø1800 mm

2. Type: 4-wheel (It adopts the ITALY PROPEZI integral casting machine, horizontal casting, the casting is the unattended operation and automatic casting. The tension wheel is in separated type, which can improve the service life of steel belt. This casting machine has obtained a national patent of China: ZL 2015 2 0432594.3.)

3. Casting bar section:        2400 mm²

4. Rolling type:                3-roller

5. Rolling pass:                 15

6. Rollers' dia.:           ø255 mm

7. Outlet rod dia.:              ø9.5  ø12  ø15 mm

8. Max. finished rolling speed: 7.66 m/s

9. Production capacity:      5.28 T/h

10. Main motor power:       355 kw(600r/min)

11. Coiling size:          ø1200- ø2200 mm

12. Max. bundling weight: 2.5 T

13. Total power:       450 kw

14. Total weight:       about 65 T

5.  Technical Data

5.1 Casting machine

1. Casting bar section:   2400 mm²

2. Type:                     H type(4-side cooling)

3. Max. casting speed:       16.8 m/min

4. Motor power:                5.5 kw

5. Cooling water pressure:        0.3-0.5 Mpa

6. Water pump:                     IS100-65-200   2 sets

5.2 Ingot tractor

1. Max. traction speed::       18 m/min

2.      Motor power:                 5.5  kw

  5.3 Scrolling Shear:

1. Shearing length:       700 mm

2. Motor power:             15  kw

5.4 Straightener

1. Max straightening speed:18 m/min

2. Motor power:            1.5  kw

3. Cylinders number:          10A-5 CBB125B200

5.5 Online heater (frequency doubling heater)

1. Heating power:          300  kw

5.6. Continuous Rolling mill

1.      Rolling type:              3-roller(5CrMnMo)

2.      Transmission ration between capstans:1:1.25

3.      Rolling pass:               15

4.      Center height:           902.5 mm

5.      Main motor power:       355 kw(600r/min)

6.      Rolling mill with active feeding ingot

5.7 Oil lubricating system

 1. Oil tank:              4m³           one set

 2. Oil pump:               2CY-12/0.33-2:  two sets

 3. Filter:                              one set

5.8 Emulsion cooling and lubricating and system

1. Emulsion pump:               IS100-65-200: two sets

 2. Cooler in plate type:     40 m²  one set

3. Filter:                        one set

5.9 Oil-free automatic rod coiling take up device (both of the concentric circles and the plum blossom taking up types are compatible with each other) or Rod quenching device and orbital coiler

1. Take up speed:          7.8 m/s

2. Take up diameter:          ø9.5 mm

3. Coiling dia.              ø1200-ø2200 mm

4. Coiling motor power   4  kw

5. Turning disc motor power:  2.2kw(2 sets)

6. Trolley Motor power:             2.2 kw

7. Trolley moving speed:        0.75 m/s

5.10  Electric control system

The main motor is in type of Siemens (produced in TianJin) DC fully-digital speed adjusting while other motors adopt frequency controlling. By adopting PLC and man-machine interface for the complete line control, it can check and display the running parameter of machines as well as indicate the breakdown. The rod coiler adopts Siemens fully digital DC speed control device to achieve the automatic coiling.

6. Equipment features

1. The width of gear box is 140mm which assures the strength of box and main transmission system, to improve the service life of the production line.

2. This line not only can produce the aluminum rod but also can produce the aluminum alloy rod.

3. Crystallizing wheel is in type of “H”, the molten aluminum can be into mould cavity smoothly, does not produce turbulence. The surface oxide film of liquid aluminum in launder and middle groove won’t be damaged which reduce the air admission again and oxidation of liquid aluminum, to assure the quality of the aluminum rod.

4. Crystallizing wheel is cooling on four sides. External and side cooling is divided into four sections, and internal cooling is divided into six sections. Each section’s supplying for water is separately adjusted, and its pressure can be shown in the pressure gauge so that make ingots even cooled, grain refined and high technological adaptability.

5. The approach bridge is two-stage type. The front stage is fixed, and the following stage can be picked up to easy changing the crystallizing wheel. Crystallizing wheel is in type of “H”, and cooling on four sides. External and side cooling is divided into four sections, and internal cooling is divided into six sections. Each section’s supplying for water is separately adjusted, and its pressure can be shown in the pressure gauge so that make ingots even cooled, grain refined and high technological adaptability.

6. The tension of steel belt is pneumatic control. Tension can be easily adjusted by adjusting the air pressure. The tension of steel belt is constant after it is set which makes for the stable die chamber.

7. All components are installed on the same body which is cast part in whole one that makes high rigidity, easy to install. Crystallizing wheel, transition wheels, and tension wheels ensure that the steel belt can not run in the same plane.

8. Casting point is just above the crystallizing wheel, to ensure level casting that protects turbulence so that the casting of molten aluminum alloy ingots without slag, porosity and loose, which can assure high quality aluminum alloy ingot in continuous casting.

9. The main box gear uses the high precision gear, and the high speed end gear uses the gear grinding craft, the noise is small and the service life is long. The internal structure of the frame is made of high strength components of the aluminum alloy rolling mill, the roll material is made of 5CrMnMo, roller, gear, and the shaft is treatment for hardening and tempering. High strength, long service life.

10. We control the temperature in rolling process, and the main method is to control the flow rate of cooling and lubricating emulsion. The cooling and lubricating emulsion of rolling stand is provided by two ways. One way is provided for cooling and lubricating of gear and bearing, while the other one is for inlet and outlet guide. The flow rate of the latter has a great influence on rolling temperature. Therefore, we independent control it by separating it which is convenient to adjust technics.

11. The coupling is in radial direction shearing, and with automatic warning device (when the shear pin of one rolling mill is opening, the console can show which one, help on time expel the breakdown.)

12. The curve wheel-in-water type pulling and coiling rod device, its advanced design features settled 5 problems: 1. In the take-up pipe canceling the grease. 2. The broken rod can be brought out automatically, without blocking the rod. 3. The aluminum rod is bright without any scratch in the whole race. 4. The innovation can make the aluminum rod deforming force and coiling releasing force in good condition to achieve best coiling (A2-A8). 5. Can reduce the hard outside soft inside problem in grease rod pulling.

13. Based on the patented product of the curve wheel-in-water type oil-free pulling and coiling rod device, our factory new develop this practical product of automatic rod coiling and taking up device. Many Buyers say it is very good after using. Automatic coiling device adopts PLC digital process to control the rod winding motor power speed slope of change, the scope, and period, while tracking speed changes in the host to feedback overlay repair capacity reduction, then to achieve the automatic matching in different host speed. Parameters to be set and fine tuned from the touch screen, in the process control, depending on the height of segment changes of coiling rods and large and small circle value, can be set with an automatic procedure to adjust correction. Automatic and manual coiling rods can be double switching, and process control is more precise. Rod coiling arrangement more neatly and compact, is better than manual coiling. Eliminating the need for manual operation, can avoid technical differences and poor condition when fatigue operation. This device comes with a remote control, which is more convenient for the switching between automatic and manual rod coiling. It can achieve one worker to coiling rod after clearly understand it.

In China, we are a state-owned factory. We can assure that it is the best one. We having the advanced design concept and manufacture technology, our products are stable and reliable. We can undertake manufacturing all kinds of complete equipments of Melting Furnace Series, Copper, Aluminum & Alloy Rod Continuous Casting and Rolling Line Series, Aluminum Strip Continuous Casting and Rolling Line Series, Wire Drawing Machine Series, etc. As a result of high quality products and outstanding customer service, we have gained a global sales network reaching Pakistan, India, Thailand, Malaysia, Belarus, Ukraine, Syria, etc. And our rod ccms have more than 70% market share in Chinese market. Our general engineer is the person who participatory designed the first line of melting furnace & aluminum rod continuous casting and rolling line in China.