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During the normal operation of the aluminum holding furnace automatic tipping system in the ingot casting and tilting process, some faults are common. However, after each casting, a significant impact noise is produced when the furnace body is tilted back. Upon investigation, it was discovered that this noise resulted from the spools of pipe rupture valves 2 and 13 being closed and then suddenly opened during the return tilt. After repeated impacts, the valve spools became damaged, the retaining nuts came loose, and the spools remained inside the valve bodies while the nuts moved freely within the piping.
In subsequent casting operations, several issues occurred. The fixing nut got stuck at the core of the electromagnetic reversing valve 8, causing the high-pressure gear pump's oil output to be directly returned to the tank through the valve without reaching the required pressure. As a result, the furnace body could not be tilted. During the casting process, the damaged core was subjected to pressure oil, which caused blockage at the pipe joint of the valve body, preventing the furnace from continuing to tilt upward and leading to casting failure. For instance, if either of the pipe rupture valves 12 or 13 was damaged, during the return tilt, both valves 12 and 13 would momentarily close. The undamaged valve core would open under the action of throttle valve 7, re-establishing the back pressure. However, the damaged valve core could not open due to the absence of spring force, blocking the oil return and preventing the furnace from tilting back properly.
As observed, these failures were primarily caused by damage to the pipe rupture valves 12 and 13, which in turn resulted from the impact forces experienced during the return movement. This recurring issue not only affected the efficiency of the casting process but also increased maintenance requirements and downtime. To prevent such problems, regular inspection and timely replacement of the affected valves are essential. Additionally, analyzing the mechanical stress on the system during the tilting process could help in developing more durable components or modifying the control logic to reduce the sudden pressure changes that contribute to valve failure.
An electric Globe Valve is a type of valve that is used to regulate the flow of fluids in a system. It is operated by an electric motor or actuator that opens or closes the valve to control the flow of the fluid. The valve has a globe-shaped body with an inlet and an outlet, and a movable disc or plug that is connected to the actuator. When the actuator is energized, the disc or plug moves away from the seat, allowing the fluid to flow through the valve. When the actuator is de-energized, the disc or plug returns to the seat, stopping the flow of the fluid. Electric globe valves are commonly used in HVAC systems, water treatment plants, and industrial processes where precise control of fluid flow is required.
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