Brief introduction
The upward continuous casting (Upcast Upcasting)system is a new technology of producing oxygen-free copper rod, having high electric conductivity and low oxygen content, which is the perfect material for electric cable and wire, as well as other electronic and electric products.
Precise process flow:
Cathode copper(clean scraps) →melting chamber→ holding chamber
Casting rod →coiling machine
Main Composed Parts
a) furnace
b) Continuous casting machine
c) Rack of directive wheels
d) Speed controller
e) Two-stroke coiler
f) Cooling system
g) Temperature test system
h) Cathode charging system
i ) Electric control system
a)Line frequency induction furnace
The line frequency induction furnace includes furnace body ,furnace frame and inductor.
The shell of the furnace is made of welded steel, inside part is made of casted refractory brick and quarts sand. Furnace frame is used for propping up the whole furnace, it is fastened on the foundation by ground bolt, inductor composed of coil, water jacket, iron core and copper channel.The high voltage side of the inductor(primary)includes coil with cooling water, the voltage could be adjusted form 90V-420V(holding furnace is 90V-380V), the low voltage side of the inductor(secondary)includes short circuited copper channel, after electrifying, it will produce big current in copper channel with the action of electromagnetism induction, and melt the copper channel and also melt the cathode at the same time .
Water jacket and coil all need to be cooled by water, the water can be recycling used, and is supplied by the cooling water system.
b)continuous casting machine
The continuous casting machine is the main part to realize the continuous upcasting which includes the traction system, the level tracking system and the crystallizer, the structure is gantry four pillar.
The traction system includes two units of servo motor, reducer and traction rolling wheel, it could make 0-600 times high speed interval motion and make the copper rod come up though the traction rolling wheel, each unit of traction system could drive 10 pair traction rolling wheel, and drag 10 pcs copper rod separately.
The automatic level track system could insure that the crystallizer is in the stable depth in the copper liquid, and to make sure the producing is continuously.
The crystallizer could freeze the copper quick into solid-state by cooling it and realize the heat exchange, each crystallizer can be change and be controlled separately
c) output frame
The output frame is set up on the upper part of the casting machine. It includes the platform, the support, the vertical guide wheel and roller. It separates and feed the casted rods into each double head take up machine without influencing each other.
d)tension frame
The take up synchronizing device is a device which is set up between the output frame and the double head take up machine. There are twenty units of displacement transducers and swing link. By controlling the angle of the swing link, the speed of the take up machine can be controlled with high accuracy and high sensitivity, meantime it can supply the reliable signal for the automatic control.
e)double head take up machine
The double head take up machine includes the traction roller, the coiling device and the coiling plate. Each unit of the take up machine includes four or three motors controlling the two sides of take up device for two rods, the max coiling weight is 3.5ton.
f)water cooling system
The water cooling system is an independent water recycling system which supplies the cooling water for the crystallizer, the water jacket and the induction coil.
