In the non-ferrous metal processing industry chain, the lead ingot casting machine,
as the key equipment connecting the smelting process and the terminal application,
is driving the development of the whole industry with intelligent and efficient
technological innovation. This collection of precision casting and intelligent control
of industrial equipment is redefining the standardized production mode of metal
material processing.
Technological breakthroughs in precision casting system
The core of modern lead ingot casting machine lies in its modular pouring system. The
quantitative pouring device adopts electromagnetic flow control technology, which can
control the pouring precision of molten metal within ±0.5%. Synchronized pouring of
multiple mold cavities is realized through PLC programming, and the single cycle time
is shortened to 12 seconds, which improves the efficiency by 300% compared with the
traditional casting method.
The innovatively designed ladder-type infiltration tank with vibration dross removal
mechanism can effectively separate the oxide impurities in the molten metal. Experimental
data show that the system's slag removal efficiency reaches 98.7%, significantly improving
the ingot surface finish. The special graphite diverter maintains stable physical properties
under high-temperature environment to ensure uniform distribution of metal liquid flow.
Innovative application of intelligent cooling system
The bottom water cooling system adopts a layered cooling structure, and the cooling
intensity is adjusted in real time by PID temperature control algorithm. The combined
application of cooling water tower and plate heat exchanger stabilizes the system
water temperature in the range of 15±2℃ as required by the process. The innovatively
designed honeycomb cooling channels increase the ingot cooling rate by 40%
while reducing energy consumption by 30%.
Temperature gradient control system through the distribution of 32 thermocouples
in all parts of the mold real-time monitoring of temperature changes, with adaptive
algorithms to dynamically adjust the cooling parameters. This intelligent temperature
control technology can refine the ingot internal grain to 0.02mm level, significantly
improve the mechanical properties of the material.
Integration innovation of automated logistics system
Dual-station chain conveyor system adopts servo motor drive, with laser positioning
device to achieve ±0.1mm positioning accuracy. The four-axis manipulator equipped
with visual recognition system can complete the stable gripping operation of 18 pieces
per minute. The self-developed anti-oxidation spraying device forms a protective
film during the conveying process, so that the thickness of the ingot oxidation layer
is controlled within 15μm.
Intelligent stacking system adopts modularized design and realizes various
combinations of stack types through programmable controller. The six degrees
of freedom mechanical arm with vacuum suction cup device can stack 25kg
standard ingot blocks to a height of 2.4m, and the offset of the stacking type
is not more than 3mm. the packaging efficiency of this system can reach 120
pieces/minute, which is more than 5 times higher than manual operation.
Multiple guarantees for safety and environmental
protection system
Totally enclosed protective cover with negative pressure dust removal system can
control the dust concentration in the working area below 2mg/m³. Emergency
cooling device adopts double circuit design, which can maintain continuous
cooling for 30 minutes in case of sudden power failure. Intelligent monitoring
platform integrates 32 safety sensors to realize real-time diagnosis and early
warning of equipment status.
The wastewater treatment system adopts three-stage sedimentation + membrane
filtration process, realizing the recycling rate of cooling water up to 95%. Waste
residue recycling device through magnetic separation + eddy current sorting
technology, so that the metal recovery rate of 99.2%. The noise of the whole
system is controlled below 75dB, reaching the first class standard of
industrial environment.
Technical considerations for equipment selection
Capacity matching: according to the average daily processing capacity to
choose a single line (5-8 tons / hour) or double line (12-15 tons / hour) configuration
Alloy adaptability: pay attention to the compatibility of the equipment for
different ratios of lead-antimony alloy, lead-calcium alloy, etc.
Mold system: preferably H13 hot work mold steel, it is recommended to be
equipped with more than 3 sets of spare molds.
Control system: self-diagnosis of faults, process parameter memory, remote
monitoring and other intelligent functions are required.
Energy consumption index: comprehensive energy consumption should be
controlled below 55kW-h/ton, and the water recycling rate should not be
less than 90%.
Driven by the dual drive of intelligent manufacturing and green manufacturing,
the new generation of lead ingot casting machine is rapidly developing in the
direction of digitalization and flexibilization. Through the in-depth application
of IoT technology, the equipment operation data can be connected to the
factory MES system in real time, realizing the full traceability of the production
process. With the popularization and application of 5G technology, remote
operation and maintenance and preventive maintenance will become the
industry standard configuration, further promoting the transformation and
upgrading of the non-ferrous metal processing industry to high-end
manufacturing.