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Ecway Technologies: Automatic Ingot Feeder For Boundary

This document describes an automatic ingot feeder system for aluminum furnaces. It uses two pneumatic cylinders to pick up aluminum ingots and move them slowly into the furnace tank via compressed air. A DC motor then controls the movement of the ingot material into the furnace using a microcontroller circuit. The system aims to more easily transport ingots into furnaces as compared to traditional difficult manual methods.

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Pooja Ban
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63 views

Ecway Technologies: Automatic Ingot Feeder For Boundary

This document describes an automatic ingot feeder system for aluminum furnaces. It uses two pneumatic cylinders to pick up aluminum ingots and move them slowly into the furnace tank via compressed air. A DC motor then controls the movement of the ingot material into the furnace using a microcontroller circuit. The system aims to more easily transport ingots into furnaces as compared to traditional difficult manual methods.

Uploaded by

Pooja Ban
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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ECWAY TECHNOLOGIES

IEEE PROJECTS & SOFTWARE DEVELOPMENTS

OUR OFFICES @ CHENNAI / TRICHY / KARUR / ERODE / MADURAI / SALEM / COIMBATORE

BANGALORE / HYDRABAD

CELL: 9894917187 | 875487 1111/2222/3333 | 8754872111 / 3111 / 4111 / 5111 / 6111

Visit: www.ecwayprojects.com Mail to: [email protected]

AUTOMATIC INGOT FEEDER FOR BOUNDARY

ABSTRACT:

 This project work titled “AUTOMATIC INGOT FEEDER FOR BOUNDARY” has been

conceived having studied the difficulty in type of aluminum ingot material.

 Our survey in the regard in several industrial boundary of furnace, revealed the facts that

mostly some difficult methods were adopted in the ingot boundary. this ingot feeder using two

pneumatic cylinder.

 An ingot is a material, usually metal, that is cast into a shape suitable for further processing.

Non-metallic and semiconductor materials prepared in bulk form may also be referred to as

ingots, particularly when cast by mold based methods.

SCOPE OF THE PROJECT:

A foundry is a factory that produces metal castings. Metals are cast into shapes by melting them into

a liquid, pouring the metal in a mold, and removing the mold material or casting after the metal has

solidified as it cools. The most common metals processed are aluminum and cast iron. However, other

metals, such as bronze, steel, magnesium, copper, tin, and zinc, are also used to produce castings in

foundries.
Molten steel from BOF/EAF is tapped into a teeming ladle. Deoxidizers, decarburizes and alloying elements

if required, are added for the final finishing with respect to oxygen content and other elements in steel. The

steel may be degassed either before or during casting. In the modern steel plants, steel is cast continuously.

In several small scale plants, particularly those based on induction melting furnaces ingot casting is

practiced. Ingot casting is done in cast iron moulds having square, round or polygon cross section. Ingots

with square cross section are used for rolling into billets, rails and other structural sections. Whereas, ingots

with rectangular cross section (also known as slab), are used for rolling into flat products. Round ingots are

used for tube making. Polygon ingots are used to produce tyres, wheels, etc. Typically an ingot weighing 5-

20 tons for rolling, whereas few hundred to 300 tons for forging.

Ingot mould types

Cast iron is used to fabricate the mould. Thermal coefficient of cast iron is lower than steel as a

result, steel on solidification contracts more than cast iron which makes detachment of ingot easier from the

mold. Inner walls of the mould are coated by tar or fine carbon. The coated material decomposes during

solidification which prevents sticking of solidified ingots with the inner walls of the mold.

Molds are essentially of two types:

i) Wide end up or narrow end down

ii) Narrow end up or big end down

WORKING

A material that has been cast into a shape in order to be transported and processed easier than  in an

unprocessed form. An ingot is typically rectangular in shape, which allows it to be stacked. Ingots are most

commonly associated with metals,


The pneumatic cylinder picks up the ingot material in to the furnace tank in slow motion by using the

compressed air. The d.c motor used to move the ingot material to furnace by using the microcontroller

circuit.

Melting

Melting is performed in a furnace. Virgin material, external scrap, internal scrap, and alloying

elements are used to charge the furnace. Virgin material refers to commercially pure forms of the

primary metal used to form a particular alloy. Alloying elements are either pure forms of an alloying

element, like electrolytic nickel, or alloys of limited composition, such as ferroalloys or master

alloys. External scrap is material from other forming processes such as punching, forging, or

machining. Internal scrap consists of the gates, risers, or defective castings.

The process includes melting the charge, refining the melt, adjusting the melt chemistry and tapping into a

transport vessel. Refining is done to remove deleterious gases and elements from the molten metal to avoid

casting defects. Material is added during the melting process to bring the final chemistry within a specific

range specified by industry and/or internal standards. During the tap, final chemistry adjustments are made.

Furnace

Several specialized furnaces are used to melt the metal. Furnaces are refractory lined vessels that

contain the material to be melted and provide the energy to melt it. Modern furnace types include electric arc

furnaces (EAF), induction furnaces, cupolas, reverberatory, and crucible furnaces. Furnace choice is

dependent on the alloy system and quantities produced. For ferrous materials, EAFs, cupolas, and induction

furnaces are commonly used. Reverberatory and crucible furnaces are common for producing aluminum

castings.

Furnace design is a complex process, and the design can be optimized based on multiple factors. Furnaces in

foundries can be any size, ranging from mere ounces to hundreds of tons, and they are designed according to

the type of metals that are to be melted. Also, furnaces must be designed around the fuel being used to
produce the desired temperature. For low temperature melting point alloys, such as zinc or tin, melting

furnaces may reach around 327° Celsius. Electricity, propane, or natural gas are usually used for these

temperatures. For high melting point alloys such as steel or nickel based alloys, the furnace must be

designed for temperatures over 1600° Celsius. The fuel used to reach these high temperatures can be

electricity or coke.

The majority of foundries specializes in a particular metal and has furnaces dedicated to these metals. For

example, an iron foundry (for cast iron) may use a cupola, induction furnace, or EAF, while a steel foundry

will use an EAF or induction furnace. Bronze or brass foundries use crucible furnaces or induction furnaces.

Most aluminum foundries use either an electric resistance or gas heated crucible furnaces or reverberatory

furnaces.

WORKING OPERATION:

ADVANTAGES

 easily maintence of furnace


 men work is reduce
 ingot material easily move to furnace using electronic control circuits

DISADVANTAGES
 Initial cost is high.
 High maintenance cost.
 There is used two pneumatic cylinder

APPLICATIONS

All material factory application


WORKING DIAGRAM:

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