The soul of metal doors - door embossing machine

Door embossing machine is a special machine for making and forming patterns for security doors, steel doors, interior doors, stainless steel doors, iron doors, etc. In recent years, it has been popular among security door manufacturers, steel wholesale markets and other factories. The machine has the features of high efficiency, convenience, safety, energy saving, beauty and low cost. The surface of the embossing roller has a clear pattern to ensure the quality of embossing on the surface of metal sheet. Many of our experienced engineers have improved the design to make the machine simple in structure and excellent in performance. Easy to operate and easy to learn, a person can learn how to do it in just a few minutes.

●Working features

Door embossing machine includes frame, guide roller, embossing roller, transmission device and adjustment device, said guide roller, embossing roller and transmission device are fixed on the frame, said guide roller has two, respectively located on both sides of the roller body of the embossing roller, said embossing roller has two placed up and down, the roller shaft of one embossing roller placed on the lower side is connected to the transmission device, and the adjustment device to adjust the gap between the two embossing rollers is set between the two embossing rollers.

⒈The whole machine adopts mechanical welding structure to achieve high rigidity; the machine is designed by ANSYS software, which can ensure the reliability and precision of the door embossing machine.

⒉The machine can emboss 100 sheets per hour (thickness between 0.4mm and 1.0mm), 70 sheets (thickness greater than 1.0mm) and 200 sheets (thickness between 0.2mm and 0.4mm).

⒊One set of molds for one design, different molds of the same size can be used for the same set of mold frames.

⒋The service life of each mold is more than 100000 sheets and the design depth of each mold is within 15mm.

⒌The column structure can achieve higher strength, more stable working process and longer service life.

●Structure type

According to the structure type, the hydraulic press is divided into two-column, four-column, eight-column, welded frame and multi-layer steel belt winding frame and other types, medium and small vertical hydraulic presses and also with C-frame type. In the vertical four-column free forging door embossing machine, the cylinder is fixed in the upper beam, and the plunger is rigidly connected with the movable cross beam, which is guided by the column and moves up and down under the pressure of working fluid. The crossbeam has a working table that can be moved back and forth. The upper anvil and lower anvil are installed under the movable beam and on the table surface respectively. The working force is carried by the frame consisting of upper and lower crossbeams and columns. Large and medium-sized free forging presses driven by pump-accumulator often use three working cylinders to get three working forces. Outside the working cylinder, there is also a balance cylinder and return cylinder to apply force upward.

●Drive system

The drive system of door embossing machine mainly has two types of pump direct drive and pump-accumulator drive. The pump of this drive system provides high pressure working liquid to the hydraulic cylinder, the distribution valve is used to change the direction of the liquid supply, and the relief valve is used to adjust the limited pressure of the system, while playing the role of safety relief. This drive system link less, simple structure, pressure can be automatically increased or decreased according to the required working force, reducing the power consumption, but the maximum working force and maximum working speed of the door embossing machine to determine the capacity of the pump and its drive motor. This type of drive system is mostly used for small and medium-sized door embossing machines, but there are also large (such as 120,000KN) free forging presses driven directly by the pump.

Pump-accumulator drive in this drive system has an accumulator or a group of accumulators. When the high pressure working fluid supplied by the pump has a surplus, stored by the accumulator; and when the supply is not enough to meet the needs, it is supplemented by the accumulator supply. With this system, the capacity of the pump and motor can be selected according to the average amount of high-pressure working fluid, but because the pressure of the working fluid is constant, the power consumption is larger, and the system has more links and a more complicated structure. This kind of driving system is mostly used for large door embossing machines, or driving several door embossing machines with one set of driving system.

● Working medium

The role of the working medium used in the door panel embossing machine is not only to transfer the pressure, but also to ensure that the working parts of the machine are sensitive, reliable, long life and less leakage. The basic requirements for the working medium of the door panel embossing machine are: ① suitable fluidity and low compressibility to improve the efficiency of the transmission; ② anti-corrosion; ③ good lubrication performance; ④ easy to seal; ⑤ stable performance, long-term work and no deterioration. Door embossing machine initially used water as the working medium, and later changed to the emulsion made by adding a small amount of emulsified oil to water to increase lubricity and reduce rust and corrosion. late 19th century, there is a mineral oil as the working medium of oil press. In the second half of the 20th century, a new type of water-based emulsion emerged, whose emulsification form was "oil-in-water" instead of the original "water-in-oil". The external phase of the "water-in-oil" emulsion is oil, and its lubricity and anti-corrosion properties are close to oil, and it contains very little oil and is not easy to burn. However, water-based emulsions are more expensive, which limits its promotion.

●Common failures

During the operation of the door panel embossing machine, sometimes the bolts will fall off and fall into the hydraulic cylinder causing serious scratches to the plunger wall. When the problem occurs, the traditional method simply cannot achieve on-site repair, and can only be disassembled and transported to the manufacturer for patch welding processing or scrap replacement. As there is no spare parts to replace, the time to re-produce parts or return to the factory for repair cannot be controlled, and the long downtime causes serious economic losses to the enterprise, and also pays high processing or repair costs. In order to meet the requirements of continuous production, it is necessary to find convenient, simple and effective maintenance means to solve the equipment problem, minimize downtime and reduce repair and maintenance costs. The polymer composite method can be used for on-site repair.

Operation steps.

⒈ With oxygen - acetylene flame baking scratch parts (master the temperature, to avoid surface annealing), the perennial seepage of metal surface oil baked out, baked to no sparks around.

⒉Surface treatment of the scratched area with angle grinder, grinding depth of more than 1 mm, and along the outer wall of the cylinder barrel grinding groove, preferably dovetail groove. Drill deeper at both ends of the scratch to change the force situation.

⒊Clean the surface with degreasing cotton dipped in acetone or anhydrous ethanol.

⒋Apply the blended repair material to the scratched surface; the first layer should be thin, even and all covering the scratched surface to ensure the best bond between the material and the metal surface, then apply the material to the whole repair area and press it repeatedly to ensure the material is filled and reach the required thickness, making it slightly higher than the surface of the cylinder outer wall.

⒌It takes 24 hours for the material to fully reach all properties at 24℃, in order to save time, the temperature can be increased by tungsten halogen lamp, every 11℃ increase in temperature will shorten the curing time by half, the best curing temperature is 70℃.

⒍After the material curing, use fine abrasive stone or scraper to repair the material higher than the surface of the outer wall of the cylinder, the construction is finished.