Layout of Alloy Shop
The Alloy Shop comprises of furnaces, Ingot casting conveyor machine and part casting machines. The details of each are mentioned below.
FURNACES
Furnaces installed in Alloy Shop are of two types. Automatically Operated Gas fired Furnace and Manually Operated Gas Fired Furnace.
Manually Operated Gas Fired Furnace
The ABL Alloy Shop contains two furnaces of this type each having capacity of 2.5 tons of molten lead. Lead ingots are loaded into the furnace by help of forklift. The furnace is ignited manually and initially pilot valve is opened for ignition then main valve is opened to get complete flame. Temperature of furnace is determined from digital thermometer.
Automatically Operated Gas Fired Furnace
There are two automatic furnaces installed in the Alloy Shop. The capacity of the each furnace is 3.5 Ton of molten lead. Lead ingots are loaded into the furnace by help of electrically operated crane. The furnace has fire blower system to ignite the main burners.
The procedure to ignite the main burner of furnace is given below.
• Blower is started to remove the accumulated gases.
• Igniter ignites the pilot flame.
• Flame sensor (Photo Sensor) senses the flame and then open main gas solenoid valve.
• Thermostatic system is used to maintain the furnace temperature.
INGOT CASTING CONVEYOR MACHINE
The machine is used to cast lead ingots. The machine setup consists of a conveyor having moulds, Lead pump and automatic furnace. The molten lead is pressurized into the lead pipe by the help of centrifugal pump. The molten lead is poured into mould and then sprayed with water to increase rate of heat transfer.
The machine is controlled by timing controller that adjusts the timing of mould filling and pouring of molten lead through pump main supply. The mould is usually filled in 5 to 6 seconds. The moulds are emptied due to inclined position of mould. These ingots are then stacked and marked with a unique number.
PART CASTING SECTION
The section is responsible for casting of battery parts including bushes, Insert M/C “U” pins, Insert I pins, Straps, Connectors, Terminal Poles, Welding Sticks and Bus Bars. The manual die casting machines are provided for the purpose. Different dies are available for each battery type. The raw material for these machines is KL-Alloy, which is produced in Alloy Shop. The KL-Alloy is melted in the furnace and then poured manually into the casting die. The solidified part is ejected afterwards.
FURNACES
Furnaces installed in Alloy Shop are of two types. Automatically Operated Gas fired Furnace and Manually Operated Gas Fired Furnace.
Manually Operated Gas Fired Furnace
The ABL Alloy Shop contains two furnaces of this type each having capacity of 2.5 tons of molten lead. Lead ingots are loaded into the furnace by help of forklift. The furnace is ignited manually and initially pilot valve is opened for ignition then main valve is opened to get complete flame. Temperature of furnace is determined from digital thermometer.
Automatically Operated Gas Fired Furnace
There are two automatic furnaces installed in the Alloy Shop. The capacity of the each furnace is 3.5 Ton of molten lead. Lead ingots are loaded into the furnace by help of electrically operated crane. The furnace has fire blower system to ignite the main burners.
The procedure to ignite the main burner of furnace is given below.
• Blower is started to remove the accumulated gases.
• Igniter ignites the pilot flame.
• Flame sensor (Photo Sensor) senses the flame and then open main gas solenoid valve.
• Thermostatic system is used to maintain the furnace temperature.
INGOT CASTING CONVEYOR MACHINE
The machine is used to cast lead ingots. The machine setup consists of a conveyor having moulds, Lead pump and automatic furnace. The molten lead is pressurized into the lead pipe by the help of centrifugal pump. The molten lead is poured into mould and then sprayed with water to increase rate of heat transfer.
The machine is controlled by timing controller that adjusts the timing of mould filling and pouring of molten lead through pump main supply. The mould is usually filled in 5 to 6 seconds. The moulds are emptied due to inclined position of mould. These ingots are then stacked and marked with a unique number.
PART CASTING SECTION
The section is responsible for casting of battery parts including bushes, Insert M/C “U” pins, Insert I pins, Straps, Connectors, Terminal Poles, Welding Sticks and Bus Bars. The manual die casting machines are provided for the purpose. Different dies are available for each battery type. The raw material for these machines is KL-Alloy, which is produced in Alloy Shop. The KL-Alloy is melted in the furnace and then poured manually into the casting die. The solidified part is ejected afterwards.