Aluminum Ingot Scalping Machine

Transmission Device and Machine Body

The transmission device and machine body are designed with a scalping transmission device composed of a welded steel cylinder structure fixed between two machine beds. The scalping transmission is guided by four rails to adjust the scalping head height. The actual height adjustment is achieved through two ball-bearing spindles driven by servo motors. The scalping head transmission device is connected to the scalping shaft via a gear-type coupling, allowing precise height adjustments of the scalping head.

A spray lubrication system operates during scalping. The spray device includes a storage container, a compressed air injector, spray nozzles, necessary solenoid valves, and spray equipment.

The machine body is a welded steel structure equipped with clamping rails. The clamping rails feature clamping devices suitable for each aluminum ingot, allowing infinite adjustments to different ingot widths using a spindle and a frequency-controlled gear brake motor.

Actual clamping operations are performed using stroke hydraulic cylinders, which are mounted on mechanically adjustable clamping brackets.

The machine is also equipped with telescopic covers to protect the machine’s sliding rails from dust and chips.

Main Scalping Head and Housing

The main scalping head is made from solid steel and flanged to the scalping shaft of the scalping transmission. The scalping head includes circumferential pockets for cutting tools, which are securely fastened with screws. It features a labyrinth-sealed scalping cover for optimized chip handling and to prevent low-pressure zones near the scalping shaft bearings.

The scalping head is equipped with cutting tools, with the tooling system consisting of robust heavy-duty cutter holder specifically tailored for the scalping head. The holder design and the recess shape of the scalping head contribute to efficient chip suction. Each cutter holder includes cutter seat and support disk. Tungsten carbide blades are securely and vibration-free mounted in the cutter seat. Clamping screws fasten the blades in place, while locking bolts provide additional security. Secondary precision cutters are mounted at a 180° offset angle.

The chip collection cover is designed to remove both short and long aluminum chips around the scalping head. Surrounding the scalping head, the chip collection cover’s design ensures high efficiency for the suction system. The verified design of the scalping head and tools ensures reliability. Furthermore, the chip collection cover is equipped with a cutting depth monitor. If the maximum cutting depth is exceeded, the equipment automatically halts the feed to the clamping bracket.

Edge Scalping Device

The scalping machine is equipped with a combined edging mechanism to simultaneously scalpe the upper and side surfaces of aluminum ingots. It includes two corner heads for scalping the edges. Upon request, an additional horizontal head for vertical edges can be added. The two corner-edge scalping heads can be positioned at various angles within a certain range. They are mounted on sliding rails on both sides of a cross joint coupling for horizontal positioning.

The edge scalping device features scale display. Once the aluminum ingot reaches the scalping position, the scalping bearing housing is clamped, and the scalping shaft moves via adjustable double-row cylindrical roller bearings with reliable performance. Axial loads are absorbed by two deep-groove thrust ball bearings, which are lubricated. A three-phase DC motor powers the scalping shaft, with speed monitored to ensure proper operation.

Chip Collection System

Chips captured by the housing are transported via pipelines to a chip crusher. The chip crusher, specifically developed for aluminum ingot scalping, is designed to ensure effective chip handling and low airflow resistance.

The chip crusher is driven by a three-phase motor and a hydraulic coupling. Both the crusher and motor are mounted on a common base frame. The crusher rotor is equipped with two cutting-edged movable suspended hammers. Each hammer has a second cavity designed exclusively for marking. A hammer can be replaced three times before requiring refurbishment.

Chips are blown by a fan into a cyclone separator, where they are separated from the air. However, this system cannot separate dust from the air.

For dust removal, an additional dust extraction system is required. Chips from the cyclone separator are sent to an intermediate collection station. They are then transferred via a vibrating washing trough to a belt conveyor and finally to a waste container.