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Traditional cylinder liner production enterprises basically use independent multiple cantilever centrifugal casting machines to produce cylinder liner castings. The production efficiency is low, the product quality is unstable, the labor intensity is high, the working environment is bad, it is a typical labor-intensive industry. With the development and progress of the society, the market demands higher and higher quality of cylinder liner, and at the same time, the cost of cylinder liner is required to be further reduced. In the environment of rising raw material and labor cost, the traditional production method is difficult to meet the market requirements and seriously restrict the sustainable development of cylinder liner production enterprises. Therefore, high efficiency, highly automated and stable production process of advanced cylinder liner casting production equipment is the necessary equipment for the future development of cylinder liner enterprises.
The double-station automatic servo-controlled cylinder sleeve centrifugal casting machine adopts the integrated structure of double main machines + multi-station auxiliary machines, with double main machines arranged side by side and controlled by frequency conversion. The double main machines share one set of auxiliary machine and casting device. The auxiliary machine is controlled by servo drive, which realizes the automatic control of the whole process of cleaning, spraying, pouring, cooling, pulling and taking out the parts of the cylinder sleeve centrifugal casting production. The high speed and smooth speed adjustable main machine, advanced multi-stage and multi-speed spraying process, and real-time monitoring and adjustment of key process parameters in the whole casting process ensure the consistency of the casting process for each cylinder liner product, completely eliminate the influence of human factors on the casting process parameters, and fundamentally ensure the stability of the inner quality of the cylinder liner casting. The machine covers an area of less space, has high production efficiency, and needs only one person to operate. It is very suitable for continuous production of single species and large quantity of cylinder liner blank castings.
Machine features:
● High speed and smooth running of the main engine --- The smooth running and speed of the pipe die is the key factor affecting the product quality. The smaller the radial runout of the die at high speed, the more uniform the wall thickness of the cylinder liner and the more stable the organization performance.
The main engine adopts the structure of four pallets, and the bearing seat is made of cast iron, which has good vibration damping. The surface of the pallets is hardened and finely ground, and the AC stepless frequency control motor + high performance vector control frequency converter is used to drive the rotation of the pallets through the high performance V-belt, which ensures the precise speed control of the pipe die.
● Accurate positioning control of auxiliary machine movements --- The cleaning, spraying and pipe pulling mechanisms are centrally arranged on a movable platform. By changing the position of the moving platform, the working position of the three auxiliary machine stations of cleaning, spraying and pipe pulling can be switched. The servo positioning control method is used to control the action position and speed of the spraying, pipe drawing and moving platform to achieve high speed and accurate positioning of the auxiliary machine to meet the strict process requirements, while shortening the action time and improving work efficiency.
●Excellent spraying quality --- The inner layer coating of the pipe mold can reduce the impact of the metal liquid on the pipe mold and lower the peak temperature of the pipe mold, which can effectively extend the service life of the pipe mold, and at the same time increase the friction between the pipe mold and the liquid metal, shorten the time required for the poured metal liquid to reach the rotation speed of the pipe mold, and also make the castings easy to be released from the mold when pulling out the pipe.
The movement of the spray bar is servo-controlled, with smooth movement and adjustable position to ensure the uniformity of the spraying layer. The moving speed of the spray bar can be divided into three adjustable sections, and the moving distance and speed of each section can be adjusted to meet the requirements of various complex spraying processes by matching the rotating speed of the pipe mold and the spraying pressure.
● Real-time monitoring of tube mold temperature and water spray cooling --- Mold temperature has a very big influence on the quality of cylinder liner. Especially the metallographic organization and hardness. If the mold temperature is too high, the wet coating is easy to burst, the coating is not uniform, the surface quality of the sleeve can not be guaranteed, and shorten the life of the mold; if the mold temperature is too low, the coating is not dry when pouring, the bubbles are not easy to precipitate out before pouring, the high temperature iron meets the wet coating which is not dry, so the sleeve is easy to produce white mouth, air holes and other casting defects.
The infrared temperature measuring device is equipped to detect the temperature of the three sections on the outer surface of the pipe mold in real time and display the temperature of the three sections on the human-machine interface. The cooling nozzles are evenly arranged above the pipe mold along the axial direction of the mold, and according to the set cooling time parameters, water is sprayed to cool the outer wall of the pipe mold during the process of iron pouring and solidification, so that the temperature of the pipe mold is controlled within the appropriate process range.
●Reliable casting taking out mechanism---The pipe pulling mechanism adopts electric + pneumatic control, which can pull out the cylinder liner casting from the pipe mold smoothly.
●Automatic pouring and accurate iron weighing----Automatic pouring consists of pouring car and tilting pouring ladle. The pouring speed is adjustable. Equipped with automatic weighing device to ensure the consistency of the weight of each batch of cylinder liner. The weight of iron water of pouring ladle is displayed on the big screen and can print the record.
● Efficient, safe, stable and flexible electrical automatic control system --- The control system adopts PLC as the control core and human-machine interface as the monitoring system to complete the automatic control of the whole process of centrifugal casting machine and the monitoring of the production working process. The control system has perfect protection measures such as over-current and overload. The process parameters of the main machine, the working position and speed of each auxiliary machine and other parameters can be set and adjusted and stored on the human-machine interface, so that the equipment has a certain flexibility and can be suitable for the production process requirements of multi-species cylinder liner castings within a certain range.
Technical parameters
No. | Name | Value | Unit |
1 | Diameter of cast pipe | Φ60~Φ120 | mm |
2 | Casting length | 1200 | mm |
3 | Diameter of mold raceway | Φ100~Φ180 | mm |
4 | Diameter of pallet wheel | Φ300x70 | mm |
5 | Distance between two pallets | 745 | mm |
6 | Distance between the ground and the center of the mold | 720 | mm |
7 | Mold speed | 0~2000 | rpm |
8 | Main motor power | 7.5 | KW |
9 | Maximum size of equipment | 6310x4200x1200 | mm |
Traditional cylinder liner production enterprises basically use independent multiple cantilever centrifugal casting machines to produce cylinder liner castings. The production efficiency is low, the product quality is unstable, the labor intensity is high, the working environment is bad, it is a typical labor-intensive industry. With the development and progress of the society, the market demands higher and higher quality of cylinder liner, and at the same time, the cost of cylinder liner is required to be further reduced. In the environment of rising raw material and labor cost, the traditional production method is difficult to meet the market requirements and seriously restrict the sustainable development of cylinder liner production enterprises. Therefore, high efficiency, highly automated and stable production process of advanced cylinder liner casting production equipment is the necessary equipment for the future development of cylinder liner enterprises.
The double-station automatic servo-controlled cylinder sleeve centrifugal casting machine adopts the integrated structure of double main machines + multi-station auxiliary machines, with double main machines arranged side by side and controlled by frequency conversion. The double main machines share one set of auxiliary machine and casting device. The auxiliary machine is controlled by servo drive, which realizes the automatic control of the whole process of cleaning, spraying, pouring, cooling, pulling and taking out the parts of the cylinder sleeve centrifugal casting production. The high speed and smooth speed adjustable main machine, advanced multi-stage and multi-speed spraying process, and real-time monitoring and adjustment of key process parameters in the whole casting process ensure the consistency of the casting process for each cylinder liner product, completely eliminate the influence of human factors on the casting process parameters, and fundamentally ensure the stability of the inner quality of the cylinder liner casting. The machine covers an area of less space, has high production efficiency, and needs only one person to operate. It is very suitable for continuous production of single species and large quantity of cylinder liner blank castings.
Machine features:
● High speed and smooth running of the main engine --- The smooth running and speed of the pipe die is the key factor affecting the product quality. The smaller the radial runout of the die at high speed, the more uniform the wall thickness of the cylinder liner and the more stable the organization performance.
The main engine adopts the structure of four pallets, and the bearing seat is made of cast iron, which has good vibration damping. The surface of the pallets is hardened and finely ground, and the AC stepless frequency control motor + high performance vector control frequency converter is used to drive the rotation of the pallets through the high performance V-belt, which ensures the precise speed control of the pipe die.
● Accurate positioning control of auxiliary machine movements --- The cleaning, spraying and pipe pulling mechanisms are centrally arranged on a movable platform. By changing the position of the moving platform, the working position of the three auxiliary machine stations of cleaning, spraying and pipe pulling can be switched. The servo positioning control method is used to control the action position and speed of the spraying, pipe drawing and moving platform to achieve high speed and accurate positioning of the auxiliary machine to meet the strict process requirements, while shortening the action time and improving work efficiency.
●Excellent spraying quality --- The inner layer coating of the pipe mold can reduce the impact of the metal liquid on the pipe mold and lower the peak temperature of the pipe mold, which can effectively extend the service life of the pipe mold, and at the same time increase the friction between the pipe mold and the liquid metal, shorten the time required for the poured metal liquid to reach the rotation speed of the pipe mold, and also make the castings easy to be released from the mold when pulling out the pipe.
The movement of the spray bar is servo-controlled, with smooth movement and adjustable position to ensure the uniformity of the spraying layer. The moving speed of the spray bar can be divided into three adjustable sections, and the moving distance and speed of each section can be adjusted to meet the requirements of various complex spraying processes by matching the rotating speed of the pipe mold and the spraying pressure.
● Real-time monitoring of tube mold temperature and water spray cooling --- Mold temperature has a very big influence on the quality of cylinder liner. Especially the metallographic organization and hardness. If the mold temperature is too high, the wet coating is easy to burst, the coating is not uniform, the surface quality of the sleeve can not be guaranteed, and shorten the life of the mold; if the mold temperature is too low, the coating is not dry when pouring, the bubbles are not easy to precipitate out before pouring, the high temperature iron meets the wet coating which is not dry, so the sleeve is easy to produce white mouth, air holes and other casting defects.
The infrared temperature measuring device is equipped to detect the temperature of the three sections on the outer surface of the pipe mold in real time and display the temperature of the three sections on the human-machine interface. The cooling nozzles are evenly arranged above the pipe mold along the axial direction of the mold, and according to the set cooling time parameters, water is sprayed to cool the outer wall of the pipe mold during the process of iron pouring and solidification, so that the temperature of the pipe mold is controlled within the appropriate process range.
●Reliable casting taking out mechanism---The pipe pulling mechanism adopts electric + pneumatic control, which can pull out the cylinder liner casting from the pipe mold smoothly.
●Automatic pouring and accurate iron weighing----Automatic pouring consists of pouring car and tilting pouring ladle. The pouring speed is adjustable. Equipped with automatic weighing device to ensure the consistency of the weight of each batch of cylinder liner. The weight of iron water of pouring ladle is displayed on the big screen and can print the record.
● Efficient, safe, stable and flexible electrical automatic control system --- The control system adopts PLC as the control core and human-machine interface as the monitoring system to complete the automatic control of the whole process of centrifugal casting machine and the monitoring of the production working process. The control system has perfect protection measures such as over-current and overload. The process parameters of the main machine, the working position and speed of each auxiliary machine and other parameters can be set and adjusted and stored on the human-machine interface, so that the equipment has a certain flexibility and can be suitable for the production process requirements of multi-species cylinder liner castings within a certain range.
Technical parameters
No. | Name | Value | Unit |
1 | Diameter of cast pipe | Φ60~Φ120 | mm |
2 | Casting length | 1200 | mm |
3 | Diameter of mold raceway | Φ100~Φ180 | mm |
4 | Diameter of pallet wheel | Φ300x70 | mm |
5 | Distance between two pallets | 745 | mm |
6 | Distance between the ground and the center of the mold | 720 | mm |
7 | Mold speed | 0~2000 | rpm |
8 | Main motor power | 7.5 | KW |
9 | Maximum size of equipment | 6310x4200x1200 | mm |
