I. Project Background and Process Positioning

This case study involves an aluminum ingot continuous casting machine, model WDL-ZDX-7, designed for automated continuous production of various aluminum ingot shapes, capable of 24-hour uninterrupted operation. After molten aluminum is injected into the chute, it is evenly distributed into the aluminum ingot molds of the chain casting machine by the distribution system, cooled and solidified by water spray, and finally demolded by a hammer demolding device.

The equipment dimensions are 7,500 mm in length, 1,250 mm in width, and 1,100 mm in height, with adjustable height. The single ingot weight is 6 kg, with a designed capacity of no less than 3 tons per hour. The casting temperature range is 680 to 720°C.

II. Matching Relationship Between Capacity and Mold Quantity

The equipment is equipped with 90 aluminum ingot molds, using chain-plate transmission for circulating casting. Based on a single ingot weight of 6 kg and a capacity of 3 tons per hour, approximately 500 casting actions are required per hour, corresponding to a mold circulation cycle of approximately 7.2 seconds per mold position. The configuration of 90 molds means there is sufficient cooling travel between the casting point and the demolding point. The residence time of molten aluminum in the mold is determined jointly by chain speed and mold spacing – this parameter matching is the physical basis for ensuring that the ingot is sufficiently solidified at demolding.

The power system employs a K97 model 3 kW variable-frequency motor with a helical gear reducer, with stepless adjustment via variable frequency. The significance of speed adjustment lies in the following: when casting temperature is lower or ambient temperature is lower, chain speed can be appropriately reduced to extend cooling time; when production pace needs to be increased, chain speed can be correspondingly increased. This adjustability enables the equipment to accommodate differences in solidification characteristics among different aluminum alloy grades.

III. Mold Material and Demolding Process

The aluminum ingot mold core adopts a coated sand casting process, with a single mold weight of 28 kg. The surface quality of coated sand molds is superior to ordinary sand molds, resulting in fewer surface defects on the cast ingots, while the mold itself offers higher dimensional accuracy and thermal stability. The 90 molds are arranged in chain-plate circulation, running synchronously with the transmission chain.

Demolding employs a mechanical hammer impact method. The reliability of hammer demolding depends on the matching between the mold draft angle design and the aluminum ingot cooling shrinkage – if the draft angle is insufficient or cooling is inadequate, the hammer impact force must be increased, which accelerates wear on both the mold and the hammer mechanism over long-term operation. The mold service life is specified at 24 months, an indicator directly related to casting temperature control, cooling intensity, and demolding operation discipline.

IV. Transmission System and Key Component Parameters

The transmission system consists of gears, chain plates, rollers, and pin shafts. The casting machine chain is 30 meters long with a pitch of 165 mm. The chain plates are made of 8 mm thick manganese plate, quenched, with built-in wear-resistant sleeves; rollers are 45# steel, and wear-resistant sleeves and pin shafts are 40Cr. This material combination addresses the operating conditions of casting machine chains under high temperature, abrasive wear, and alternating loads – manganese plate quenching provides surface hardness for the chain plates, while 40Cr pin shafts provide core toughness.

There are 4 transmission gear disks, made of 45# steel with high-frequency quenched tooth tips, 8 teeth at the rear and 8 teeth at the front. There are 2 transmission shafts, lathe-machined, with both driving and driven shafts at Ø70, material 45# steel. The coupling flange disk adopts a sprocket plus double-row chain clamp-type connection, which transmits torque while allowing compensation for certain installation deviations.

The frame is welded from channel steel and rectangular tube, with structural rigidity and dimensional stability meeting the load-bearing requirements of a 7.5-meter-long equipment.

V. Cooling and Distribution Systems

The cooling method is water spray. The water distributor is a cast-iron part with 8 nozzles, uniformly spraying cooling water onto the bottom and sides of the molds. The cooling water collection system is included in the equipment supply scope, with sprayed water collected and recovered to prevent workshop flooding.

The distribution system moves synchronously with the molds. Molten aluminum enters the distributor through the chute and is evenly injected into each mold. The purpose of synchronous movement is to ensure that the distributor outlet and the mold pouring gate remain aligned during the casting instant, avoiding aluminum overflow or uneven pouring that would cause ingot weight deviation.

VI. Electrical Configuration and Operational Stability

The power supply is 380V three-phase four-wire 50Hz AC, customizable as required. The control system includes an inverter, with Delta as the inverter brand. Electrical components are all international brands with reliable performance. All accessories are market standard parts, offering high convenience for procurement and repair.

Operational stability is ensured by two aspects: first, variable frequency speed adjustment allows continuous adjustment of chain speed according to process requirements, avoiding rigid impact at fixed speeds; second, the K-series helical gear reducer offers smoother transmission than ordinary gear reducers, with better noise and vibration control under long-term continuous operation.