Research On Automatic Demoulding Device For Large Zinc Alloy Ingots

China has become the largest producer and consumer of zinc,with a huge demand for it.Currently,over half of zinc-based products are processed into hot-dip galvanized products,and the quality of hot-dip galvanized alloy ingot products greatly affects the surface quality and service life of the coating.In the production process of hot-dip galvanized alloy ingots,operations such as pouring,water cooling,demoulding,and handling are mainly done manually,which results in low mechanization,high labor intensity,difficult product quality control,and non-compliance with high-temperature molten metal management standards.This has become a chronic problem in the industry.To solve these problems,this paper focuses on the water cooling process and demoulding,two key technologies in the production process of hot-dip galvanized alloy ingots,and designs an automatic demoulding device that achieves automatic water cooling and demoulding of zinc alloy ingots,thus improving product production efficiency and quality.The thesis mainly completes the following tasks:The production site of zinc alloy ingots was evaluated and analyzed using the fault tree analysis method,and the factors that affected the normal operation of each process were identified.The probability of accidents was calculated,and the processes that needed improvement were determined.The research objectives and requirements were proposed.According to the process requirements,the three-dimensional model design of the automatic demoulding device was completed using Solid Works.The functions and design ideas of each part were described in detail.The parameters of the demoulding slope,mold wall thickness,and cooling chamber volume were calculated,and the overall size of the water-cooled mold was determined.Based on the demoulding load requirements,the calculation and selection of hydraulic components such as hydraulic cylinders,oil pumps,and motors of the automatic demoulding device hydraulic system were completed.The work process of the automatic demoulding device was designed according to the product production process.The hardware selection of the control system,control scheme design,and PLC programming method ladder diagram were used to program the automatic demoulding system.The system was debugged using PLCSIM to make the automation production technology more mature.An experimental prototype of the automatic demoulding device was made,and demoulding experiments were carried out.The experimental results showed that the automatic demoulding device could achieve automatic water cooling and automatic demoulding processes without affecting the surface quality of hot-dip galvanized alloy ingots.The cost and benefits of the automated demoulding device after it is put into operation were analyzed and calculated.Assuming that the device is formally put into operation,it will reduce the production time of each production line by 50%,reduce labor costs by more than 300,000 yuan per year,and reduce the probability of production accidents by 27.57%.