●Main uses and features
The equipment adopts three beams and eight columns body structure, the main load is shared to eight columns, the force is uniform, the deformation of the body is small; the slider adopts four columns for guidance, thin oil lubrication. The equipment power mechanism is placed on the right side of the body, the hydraulic system is equipped with large diameter two-way cartridge valve, the electrical control system is controlled by PLC, the control panel is placed on the electric control cabinet in front of the oil tank on the right side, the equipment has three operation modes: adjustment, manual and semi-automatic, the working pressure, working speed and stroke size of the equipment can be adjusted manually within the specified range according to the process requirements.
The machine is composed of two major parts: the main machine and the control.
The host part is composed of body, main cylinder, top cylinder, liquid-filled valve, etc., and the control part is composed of power mechanism, range limiting device, hydraulic far control device and electrical control box, etc. Each part of the mechanism and role is described as follows.
⒈The host part
⑴Body (see outline drawing)
The body is composed of upper beam, slider, table, column, fastening nut and adjusting nut. The upper beam and table through the eight columns and sixteen fastening nuts, sixteen adjusting nuts combined into a fixed frame. The accuracy of the machine is adjusted by the adjusting nut and the fastening nut fixed on the upper end. The slider and the main cylinder piston are connected by flange and screw, and rely on four columns to guide the up and down movement. The slider is equipped with guide sleeve. The slider and the working table are equipped with T-slots, which can be equipped with M24 screws to fix the mold (attached figure 2)
The main cylinder is a plunger cylinder, the cylinder body is fastened to the upper beam with screws. The main cylinder is equipped with a liquid filling valve at the end and a plunger inside the main cylinder. The two-way combination seal is used to ensure that the cylinder does not leak when it is under high pressure.
Liquid-filled valve is composed of valve body, piston, main spool, unloading spool, etc. Its action.The action is similar to that of the liquid-controlled check valve. When the slider fast downward, the pump oil can not be supplied in time to the main.When the slider moves down quickly, the oil from the pump cannot supply the upper chamber of the main cylinder in time, thus causing negative pressure, so that the main spool is sucked open and a large amount of oil from the filling cylinder enters the upper chamber of the main cylinder.In the opposite direction, rely on the control oil to open the main spool, the main cylinder of a large amount of oil back to the filling cylinder.
The ejector cylinder is installed on the base, above the table and the lower top plate, the table is arranged with T-slot, the size is the same as the slider. The size of the standard top plate is 1590mm*510mm, which can meet most of the customers' working requirements. The oil in the return stroke of the ejector cylinder returns to the tank through the filling valve to improve the working efficiency.
⑴Power mechanism consists of lower oil tank, pump set, valve integration, etc.
①Oil tank (lower oil tank)
The lower oil tank is welded and has a volume of about 1800 L. The oil tank is mounted on the base frame together with the pump group, and the base frame is placed on the ground on the right side of the press. The oil tank is welded steel plate structure, and the oil tank accessories include cleaning window, liquid level meter, oil release plug, oil filter, etc. When refilling the equipment, the height of refueling should be about 50mm below the upper scale of the level meter (at this time, the oil cylinder piston should be backed to the bottom of the cylinder). The oil filter should be cleaned regularly to ensure the cleanliness of the oil in the tank.There are two oil tanks on the tank, as the main cylinder empty range refueling and return when the oil discharge oil storage, the total volume of the tank is 2000 liters.
Equipment pump group consists of two groups of Y2-250M-6 motor + 160YCY14-1B axial piston pump, the oil suction port and the oil tank is equipped with an oil filter, the valve should be opened before starting the oil pump, and the filter valve should be removed before dismantling and repairing the oil pump.
Equipment valve integrated installed in the oil plate, valve integration is described in the introduction of the hydraulic system.
⑵Range limiting device.
It consists of three GAM8-18GMA1 proximity switches and switch frame, bumpers.
They are used as upper and lower limit position limit respectively, and as fast downward conversion to slow downward limit, and they can all be adjusted according to the process requirements. In addition, 2 GAM8-18GMA1 proximity switches and switch frame are used as the upper and lower limit position limits of the lower top plate respectively.
⑶Electrical control box.
The electrical control box is a welded metal sheet box for installing electrical components and button plates.
⑷Hydraulic remote control device.
Including pressure gauge, regulator, are installed in the tank instrument control panel.YN-100ZQ type pressure gauge indicates the pressure of the main cylinder, and can send a signal according to the adjusted pressure.
The hydraulic system consists of pumps, valves, motors, etc. With the control of the electrical system, the hydraulic machine completes a series of process cycle actions. The following is a brief description of the hydraulic system operation process with reference to the hydraulic system schematic diagram.
Press the "start" button, the motor buck delayed start rotation, dragging the pump rotation, the oil pump output oil through the valve 2.7 unload back to the tank, the oil pump airlift.
⒉Fast downward movement of slider.
Press the "press" button, solenoid valve YA1, YA3, YA4, YA5 energized, the oil pump output oil through the plug-in 2.1, one-way valve 2.8 into the upper chamber of the main cylinder, the lower chamber of the main cylinder discharge oil through plug-in 2.3, plug-in 2.5, 2.6 back to the oil tank. The slider moves down by its own weight causing negative pressure in the upper chamber of the main cylinder, thus sucking open the liquid filling valve, so that a large amount of oil enters the upper chamber of the main cylinder through the valve to fill the volume of the upper chamber and realize the rapid downward movement of the slider.
⒊Slow speed pressing.
Slider fast down to the travel switch SQ2, SQ2 sends a signal, solenoid valve YA3 DE-energized, the main cylinder lower cavity oil discharge need to overcome the support valve back pressure back to the tank, the main cylinder lower cavity pressure increases, the upper cavity pressure increases, the liquid filling valve closed, the main cylinder upper cavity by the oil pump oil supply, the slider reality slow down action.
Before the return of the slider, in order to reduce the shock vibration of the system, the main cylinder upper chamber need to unload the pressure first, after the return, pressure-holding time to the time relay KT3 sends a message, solenoid YA10 energized, solenoid YA12 energized, the main cylinder unload. Wait until the pressure is reduced to the set range, YA11 energized, open the liquid filling valve and start the return stroke.
When the main cylinder pressure unloading to the lower limit of the electric connection pressure gauge, KT3 lower limit to send a signal, solenoid YA11
YA2, YA6, YA12 energized, the pump supply oil through valve 2.3 into the lower chamber of the main cylinder, the main cylinder upper chamber discharge oil through the liquid filling valve back to the tank, the slide back (return force by the return regulator adjustment), return to the proximity switch SQ3, SQ3 signal, electromagnet are de-energized, return to stop.
⒍Top cylinder ejecting.
According to the PLC command, solenoid valve YA1, YA7 energized, the oil pump output oil into the lower chamber of the top cylinder through the plug-in 4, the top cylinder upper chamber discharge oil through the plug-in 3 back to the tank. When up to the upper limit of the top cylinder (SQ4), solenoid valve YA1, YA7 power off, the top cylinder ejected to stop.
⒎Top cylinder return.
According to the PLC command, solenoid valve YA1, YA8 energized, the oil pump output oil into the top chamber of the top cylinder through the plug-in 2, the top cylinder lower chamber discharge oil through the plug-in 5, and the auxiliary filling valve back to the tank. When the return stroke to the lower limit of the top cylinder (SQ5), solenoid valve YA1, YA8 power off, the top cylinder return stroke stop.
The machine electrical system is divided into four parts, see the electrical schematic Main circuit: three-phase AC 50HZ, 380V~ power supply, mainly including air switch, AC contactor, thermal relay and three-phase motor, etc. The motor model rules are as follows:Y2-250M-6 30KW 380V~ 980 r/min 2 sets.
⑴Action selection line.
This machine is equipped with "manual" and "automatic" two kinds of ways. The operation button is on the top of the electrical operation box.
⑵Adjust the working mode.
SA1" rotate to the "manual" position (i.e. contact 11 ~ 18 disconnected), then press a button to get the corresponding point action.
⑶Automatic mode of operation.
Divided into two kinds of fixed pressure and fixed range.
①Fixed pressure mode
Turn "SA1" to the "automatic" position (contacts 11 ~ 18 on), then press SB5, SB6, the slider can be fast down, slow pressurization, pressure relief delay after the return and return to stop, to complete a cycle.
②Fixed range mode.
First adjust the travel switch SQ3 to the desired position, when the slider downward pressure, collision SQ1 immediately and automatically return (the pressure relay should be adjusted to slightly greater than the pressurized pressure).
The control line adopts 36V DC power supply, obtained by stepping down the voltage through the control transformer, for the AC Current contactor, intermediate relays, time relays and other normal work.
This machine 10 AC solenoid, its main technical specifications are as follows: armature stroke 8mm(actual use of 3.5mm), the minimum driving force of 30N.
⒉Electrical principle description.
Now take the semi-automatic setting mode as an example to explain the following.
⑴First of all, the air switch "QF" on, the signal light "HL1" on.
⑵Press the "motor start" button ("SB2") AC contactor KM1 to get power.
After a delay, the star-delta voltage reduction start. (Note that the direction of the motor must be consistent with the direction of the oil pump label), the motor and the oil pump are in the airlift state.
⑶Press "SB5" and "SB6" with both hands to energize intermediate relay KA1.
At the same time, YA1, YA3, YA4, YA5, YA9, YA12, the slider fast downward, when down to the proximity switch "SQ2", electromagnet YA3 power loss to slow down. When the pressure rises to the electric contact pressure gauge to adjust the pressure limit, its contacts (11 ~ 30) closed, the relay KA7 and self-preservation, so that KA1 disconnection.
⑷Unloading pressure fast return.
When KA2 is energized at the same time, turn on YA10 to make the master cylinder unloading pressure. When unloading to a certain pressure, turn on YA11, delay to the specified time, YA10 disconnection, YA6 energized, the main cylinder back.
⑸Return to stop.
When the return stroke touches the travel switch SQ3, YA2, YA6, YA11 power off, the return stroke stops.
Press the ejector button, solenoid valve YA1, YA7, YA11 energized, pump oil supply through solenoid valve YA7 into the lower chamber of the top cylinder. Top cylinder rise, pay attention to the top cylinder stroke can not exceed 150mm.
Press the return button, solenoid valve YA1, YA8 energized, pump oil supply through solenoid valve YA8 into the upper chamber of the top cylinder, the top cylinder down.
⑴The main circuit short-circuit protection by the air switch directly, control electrical protection.Use small circuit breaker.
⑵The motor overload protection is the use of thermal relays.
⑶The machine in the event of failure, you can press the emergency stop button SB1, so that the hydraulic machine all stop working.
⑷The main machine, power mechanism, electrical box have grounding device, the user should install.The user should use 6mm² soft copper wire to connect reliably to the total protective ground of the scene respectively.
⑸Please provide your own photoelectric protection device, we only leave the interface.
●Installation and test drive
⒈ The preparation before installation.
⑴Remove the packing box after the machine arrives at the factory and remove the bolts that fix the parts.
⑵lifting should pay attention to the center of gravity of the other parts, reasonable choice of lifting holes and lifting position.When lifting the steel rope and another part contact should be padded.
⑶The machine should be installed on a solid concrete foundation (see attached drawing for details of foundation requirements).Pay attention to the per-buried wire inlet pipe.Prepare a test pressure mold, the height is not less than 150mm, the area is not less than 2200mm*1000mm parallelism of the upper and lower sides of the error should not be greater than 0.05mm.
⑴ Place the table on the foundation, calibrate the table with a level, the level error should be no more than 0.2/1000.
⑵Place the test press mold in the center of the table.
⑶Place the slider on the test press mold, and align the four holes with the table.
⑷Install the eight columns into the slider and table respectively, and screw the nuts at the lower end.
⑸Install the upper cross beam assembly and nuts.
⑹Install the range limiting device.
⑺Position the oil tank and electrical control box according to the shape diagram.
⑻Connect the pipeline according to the shape diagram and hydraulic principle diagram.
⑼Connect the power supply and wiring according to the electrical schematic diagram.
⒈The preparation before the test run.
⑴The operator must understand the hydraulic and electrical working principle in detail before the test run, and understand the function of each part of the machine.
⑵Thoroughly clean the machine, remove all the exposed surface of the anti-rust grease, and thoroughly clean the oil tank.
⑶Inject filtered oil into the tank through the empty filter port of the tank to 2/3 of the liquid level meter, and the liquid-filled cylinder is not lower than the oil return port. (Liquid-filled cylinder oil is automatically entered by the machine when it is turned on)
⑷Strictly check all parts of the machine, requiring correct installation, solid connection, electrical connection.The ground is reliable, and the exposed surface of the moving part of the machine and the lubrication points are filled with lubricant.
⑸Unscrew the oil pump back to the oil port connector, inject the filtered oil, fill up until.
⑹The regulating handle will be properly relaxed.
⑴Turn on the power, start the motor, and pay attention to whether the motor steering is consistent with the arrow on the pump body.If it does not match, change the phase line of the motor.
⑵Make the pump idle for 20 minutes.
⑶Make the master cylinder piston move up and down several times by pointing, but the first time you must first press the "return" button program, then connect with the slider, and tighten the nut in the pressure-holding state when the oil pressure of the master cylinder is adjusted to 6MPa.
⑷Calibrate the accuracy according to the requirements of the certificate.
⑸Set the test block to the center of the table and test pressure, test pressure 8, 18, 25MPa four pressure, regulator should be sensitive and reliable.
⑹Check the pointing, manual, semi-automatic no-load and full-load according to the process requirements test.
⑺In the load test, check whether the pipe joints and seals are leaking oil at any time.
If there is oil leakage and abnormal conditions, should immediately stop and adjust to, is strictly prohibited not to stop to repair.
⑻Calibrate the accuracy of the machine again.So far the installation and commissioning is over, can be put into production. A brief description of the common faults, the actual use of the fault should be found in the first analysis, check one by one to eliminate.
●Fault and troubleshooting method
Before troubleshooting should understand the performance of the machine, know the maintenance and safety operating procedures.
Otherwise, the pump, valve, electrical disassembly and repair. Generally, we should ask our factory professionals or people with certain professional knowledge to carry out, in order to avoid equipment and personal accidents. The following is a list of common faults and methods of elimination.
|No.||Fault phenomenon||Cause||Elimination method|
|1||Failure to operate||Poorly wired or mis-wired electrical appliances||Check the electrical|
|Insufficient fuel tank filling||Refuel to the oil mark|
Air in the system
Air in the suction port
|Check the suction port for air intake|
|Multiple up and down movements to pressurize|
|Improper accuracy adjustment||Readjustment accuracy|
|Oiling the column|
|3||Slider down with pressure||Excessive support pressure||Adjust the support valve so that the upper cylinder does not carry pressure|
|4||The slider slides down seriously after stopping||Leakage of cylinder port seal||Observe the cylinder port to find oil leakage more|
|Valve 2.3 valve port is not tight||Checking and researching|
|Valve 2.5 adjustment pressure is too small or the valve port is not tight||Adjust the pressure and check the valve port|
|5||Pressure gauge pointer wobbles severely||Air in the pressure gauge oil circuit||Slightly loosen the connector to release air when pressing up|
|Pipeline mechanical vibration||Fasten the pipe rack|
|Damaged pressure gauge||Replacement|
|6||Dropping pressure too fast when keeping pressure||Severe internal leakage of the system||Check if the liquid filling valve is closed|
|Check each seal separately|
|Each valve port involved in pressure-holding is not tight or the pipeline is leaking oil||Check the liquid filling valve, valve 2.8|
|Damaged in-cylinder seal||Seal replacement|
●Maintenance and safe operation
The correct use of hydraulic presses, careful implementation of maintenance and compliance with safety operating procedures, is to reduce hydraulic press failures, prolong the life of hydraulic presses.
Reduce hydraulic machine failure, extend the service life of the hydraulic machine, to ensure safe production of the necessary conditions. Therefore, hydraulic press operators and maintenance personnel, must have a comprehensive understanding of the structure of the hydraulic press, performance, maintenance requirements and operating procedures.
⑴The hydraulic machine used in the oil must go through strict filtration before injecting into the tank.In winter, use No. 32 hydraulic oil (or mechanical oil), and in summer, use No. 46 hydraulic oil. (The first refueling amount ~ 3200 liters)
⑵The oil temperature in the tank during the work should be between 10 ~ 60 ℃, if the oil temperature is too high.then should stop working, wait for the oil temperature to cool down before working, so as not to damage the oil pump and seals.
⑶The oil must be kept clean, replaced every six months, the first use of time should not exceed 2 months.If the oil has not deteriorated, it can be used after fine filtration, and the oil filter in the oil tank should be cleaned regularly.
⑷Keep the surface of the column and piston rod clean frequently, and inject oil at least four times per shift.
⑸Check the high pressure pipeline every day, if there is leakage, it should be eliminated in time.Abnormal phenomenon should be stopped to check and repair.
⑹Check regularly whether the oil pump, valve, pressure gauge and oil filter are working normally.The pressure gauge should be calibrated once every six months.
⑺When the hydraulic machine is out of use for a long time, the processing surface should be cleaned and coated with antirust Oil, and the table with the same height support (pillow or cushion).
⒉Safety operating procedures.
⑴Do not understand the hydraulic machine structure, performance and operating procedures, you can not start the hydraulic machine without permission.hydraulic press.
⑵Hydraulic machine in the process of work or starting pressure, it is strictly prohibited to carry out maintenance or adjustment the mold.
⑶The hydraulic machine found abnormalities (such as unreliable action, vibration, noise, etc).Must stop the pressure, disconnect the power supply for maintenance, not allowed to "sick" work.
⑷The slider is strictly prohibited to exceed the maximum stroke work, (mold closure height shall not be less than 120mm, nor shall the bias load be too large (the maximum bias load shall not exceed 30 mm).
⑸When the ram is working, it is strictly forbidden to put the hand or head into the effective area of the table.
⑹It is strictly forbidden to tighten pipe joints and nuts with high pressure when the hydraulic machine is working.
⑺Check the stroke switches and safety protection devices frequently to ensure reliable operation of the machine work.
⑻When adjusting the mold or repairing under the slider, the slider must be supported by a cushion, not pressure to prevent the slider from slipping to ensure safety.
⑼The support of the slider of this machine is to rely on the primary support valve port 2.3 and secondary support valve port 2.5 to achieve together. The normal use pressure of the support valve is adjusted to support the weight of the slider and the mold. Both the primary and secondary support valve ports must be reliably closed during shutdown, so please check them frequently. When the no-load slow down speed of the ram is greater than 15mm/s. It indicates that the second stage support valve is adjusted too loose or the valve is damaged. The press is already in an unsafe condition, and must be stopped to check and troubleshoot.