3 Effective Strategies for Hydraulic System Troubleshooting in Shearing Machines

As someone deeply involved in industrial machinery, I frequently encounter issues related to hydraulic systems, especially in shearing machines. Understanding hydraulic system troubleshooting of shearing machines is vital for maintaining efficiency and minimizing downtime. In this article, I will explore common problems that arise within hydraulic systems and provide practical solutions to address them. By effectively troubleshooting these issues, operators can ensure their machines operate smoothly, ultimately enhancing productivity and performance in metal fabrication. Let’s take a closer look at how to resolve these hydraulic challenges effectively.

Hydraulic System Troubleshooting

Trouble phenomenon: no pressure can be established, no action on the upper knife holder.

Cause of failure: Poor contact of the electrical plug of the electromagnetic directional valve.

hydraulic system troubleshooting method: Check the electrical plug. The spool of the electromagnetic directional valve is blocked by debris or does not act on the roughened surface; the sealing port of the spool of the combined valve has debris and does not play a sealing role; each orifice in the combined valve is blocked and checked for disassembly and cleaning. The return stroke of the upper knife holder is slow or cannot return to the top dead center. The action sequence of the upper knife holder and the pressing cylinder is not coordinated; the nitrogen pressure of the return cylinder is insufficient. Check and adjust it to the rated pressure separately.

Adjustment and operation of shearing machine

(1) Adjustment of cutting edge clearance

Whether the cutting edge clearance is adjusted properly is an important factor that affects the cutting quality and prolongs the life of the blade. When adjusting the gap, temporarily loosen the locking screw, then turn the handle to the desired scale value, and then tighten the screw. The ball valve is used to measure the uniformity of the gap between the upper and lower blade edges.

The specific method is to use a single stroke, when the upper and lower racks reach the bottom dead center, that is, quickly turn the ball valve to close the oil path, so that the upper knife holder stops at the bottom dead center. Then continue to open and close the ball valve by a small amount, so that the upper blade holder rises step by step over the full stroke, at this time, the uniformity of the blade gap can be measured step by step.

Blade clearance should typically be set to about 10% of the material thickness.Use the adjustment screws to set the blade gap, ensuring even clearance across the entire cutting length.

(2) Preparation before operation

① Clean the oil on the surface of each machine, pay attention to the line on the cut-off valve should be in the open position.

② Inject grease into each lubricating part.

③ Add L-HL46 mechanical oil to the oil tank (the oil must be clean).

④ Ground the machine, press the power supply, and check the coordination of the actions of the electrical appliances.

(3) operating

① Turn on the power and check all controls for proper function. Turn on the machine for several cycles. After ensuring that there are no abnormal conditions, try to cut sheets of different thickness (from thin to thick).

② During the shearing process, make a test cut with scrap material to ensure settings are correct. turn on the pressure gauge switch and observe the pressure value of the oil line. If there is any abnormality, adjust the relief valve to meet the requirements.

③ During operation, if abnormal noise or overheating of the fuel tank is found, stop the vehicle immediately and check that the maximum temperature of the fuel tank does not exceed 60 degrees. Watch for unusual sounds or movements during operation.

④ Post-Operation Checks，Always power down the machine after use.

Safety technology and maintenance of shearing machine

(1) The operator must be familiar with the structure and performance of the shears. Shearing machines are operated by most people at the same time, so someone must be in charge of directing production.

(2) Never put your hand between the upper and lower blades to avoid accidents.

(3) Do not put all the sundries and tools on the workbench to avoid accidents caused by rolling into the blade.

(4) The sharpness of the blade should be checked regularly. If it is found that the blade is blunt, it should be sharpened or replaced in time. The sharpness of the blade only needs to sharpen the thickness of the blade.

(5) All parts of the shears should be checked regularly to keep the machine and the surrounding area clean, and the cable insulation is good.

(6) The mesh oil filter installed on the oil suction port of the oil pump should be regularly checked and cleaned to keep the oil filter with the proper oil flow. If the oil filter is clogged and the oil flow is reduced, the oil pump will be sucked down, affecting the life of the oil pump.

(7) When the pressure of the return cylinder is low, the return cylinder can be inflated. The method is: remove the protective cap and the gas valve cap, install the inflation tool, the other end of the inflation tool is connected to an ammonia gas bottle (no oxygen), open the inflation tool, and slowly open the nitrogen bottle stop valve, pay attention to the inflation pressure gauge.

Close the cut-off valve of the gas cylinder immediately to 6.0MPa. Close the inflation tool, open the inflation tool, and install the air valve cap and protective cap. 8. Check the nitrogen pressure in the return cylinder every three months. If the pressure is lower than the specified pressure, it should be filled with nitrogen.

Hydraulic system troubleshooting of shearing machine is essential for maintaining operational efficiency. By understanding hydraulic system troubleshooting, you can minimize downtime and ensure your machinery performs at its best. Always refer to the manufacturer’s manual for specific guidelines and maintenance schedules tailored to your machine model. With proactive care and attention, your hydraulic system can remain a reliable component of your metal fabrication process.