W24 Angle Bending Machine Operation Procedure and Method
- Ⅰ. Application
- Ⅱ. Structure and Performance
- 2.1 Structure
- 2.2 Performance
- Ⅲ. Pre-bend and Curl
- 3.1 Bending of profiles
- 3.2 Curling method
- 3.3 Profile pre-bending and bending process
- 3.4 bending range
- 3.5 Profile bending mold and preparation combination.
- Ⅳ. Lubrication
- 4.1 Selection of Lubricants
- 4.2 Lubrication System and Precautions
- Ⅴ. Hydraulic Principle
- 5.1 Hydraulic principle
- 5.2 Selection of Oil
- 5.3 Use and Maintenance of Hydraulic System
- 5.4 Common Faults and Troubleshooting
- Ⅵ. Electrical system
- 6.1 Power Switch:
- 6.2 Control power supply:
- 6.3 Starting and indication of the motor of the oil pump
- 6.4 Rotation of the main drive:
- 6.5 Edge roller lifting:
- 6.6 Support Roller Rotation:
- 6.7 Support Roller Lifting:
- Ⅶ. Installation and Commissioning
- 7.1 Installation of the machine
- 7.2 Test Run
- 7.3 Empty Test Run
- 7.4 Commissioning requirements
- 7.5 load test
- Ⅷ. Operation
- 8.1 Security Operations
- 8.2 Maintenance of the Machine
The W24 Series Angle Bending Machine is a three-roller Angle Bending Machine with arc down regulation. It is a general-purpose device specially used for roll forming of various profiles. It can be used to make rounds, arcs, spirals and other workpieces in petroleum products. Chemical, hydropower, shipbuilding machinery manufacturing and large-scale steel construction in various industries, has a wide range of applications.
|Sectional modulus cm3||10-20||16-45||45-75||75-140||140-180||180-250||250-320||320-400||400-500||500-600|
W24 Angle Bending Machine is a three-axis roller bending down structure Angle Bending Machine, mainly consists of working bed, side roller part, support roller device, main drive part, sensor device, mold part, hydraulic pressure, electronic control and other parts . The working bed adopts a steel plate welded structure, and all mechanical parts are installed inside and outside the working bed, forming the mechanical part of the W24 Angle Bending Machine. The main drive is driven by two hydraulic motors. One of the hydraulic motors is transmitted to the lower roller through a gear transmission, so that the lower roller obtains the required linear speed and torque, and the other motor drives the upper roller. The lifting movement of the lower roller and the supporting roller is driven by a hydraulic system.
The hydraulic system and the electronic control system are respectively a unit body, which is connected with the execution parts of the machinery through the pipeline and the electric wire. The hydraulic pump station and the operation table can be placed according to the position of the work site, and the host is horizontally installed.
W24 Angle Bending Machine can add different molds and additional devices for roll bending according to the user's requirements for the bending process of different profiles and the working accuracy of the workpiece.
W24 Angle Bending Machine is an arc down-adjusting structure that allows for pre-bending of the ends of the profile with the remaining straight edge being less than or equal to twice the height of the profile. W24 Angle Bending Machine's three work rolls are all active rolls and use rolling friction for high efficiency and energy saving.
The main drive is driven by the hydraulic system through the hydraulic motor and a set of gears to drive the upper roller and the two side rollers to do the rotary motion. The two side rollers are driven by the oil cylinder and can perform arc type lifting movement around the center axis. Its function is the bending of the profile; the support roller can be lifted and rotated by the cylinder drive, and its function is to prevent the profile from forming in the bending process. Flex deformation, to ensure the accuracy of bending the workpiece.
All movements of the machine are driven by the hydraulic system. The electronic control system controls the system in a centralized manner. A digital display system is installed to display the up and down stroke amounts of the two rollers, which facilitates the operation and control of the roll forming of the workpiece.
(1) During the rolling process, the rotation of the three-axis roller and the side roller lifting movement cannot be performed at the same time to avoid failure.
(2) When the roller shaft is raised to the highest position, lifting the backup roller is prohibited to avoid malfunction.
Profile bending can be divided into symmetrical and unsymmetrical bending:
3.1.1 Symmetrical curling: The two moving side-bend rolls are symmetrically arranged relative to the fixed upper-axle roll for profile bending. The symmetry curve curl radius consistency is good. For a regular curl.
3.1.2 Asymmetrical curling: The two moving side-bend rollers are arranged asymmetrically with respect to the fixed upper-shaft roller, and this type of bending is generally used for pre-bending of the profile head.
There are three types of roll bending methods, as shown in the figure.
Curling method 1
Suitable for heavy workpieces, after being bent into a circle or rolled to a certain arcCut the remaining straight edge.
Curling method 2
Suitable for medium or small profile or single piece rolling, must be cut before rolling, and bent at the end using asymmetric bending.
Curling method 3
Applicable to various profiles, the bending diameter is larger than the diameter of a single bent workpiece.
The right shaft roller is in the lower limit position. The left roller moves to contact the workpiece and clamps the workpiece with the spindle roller.
The right roller slowly rises, starts rolling, pre-bends between the main roller and the left roller
The left shaft roller is down, while the right shaft roller is upward, the material is sent to the left, the three-axis roller starts to be rolled, and the pre-bend is made between the spindle roller and the right shaft roller
Pre-bending and rolling ends, discharging starts the next cycle
A variety of profiles can be bent by changing or blending a combination of molds.
All kinds of profile bending size and scope please refer to
The profile bending mold and the preparation combination are designed according to the type and specification of the user's rolled profile. The profile type of the user's rolled profile is different, and the preparation of the mold is also different.
The equipment comes with a set of molds, according to the user's requirements and the contract.
The bending method and bending process of various profiles can be found in 3.2 Profile Rolling Method, 3.3 Profile Prebending and Curling Process.
3.6.1 Overview of Rolling of Flat Steel and Square Steel
Flat steel and square steel are symmetric sections, which are easy to curl. Asymmetric bending is used for pre-bending. A certain degree of distortion is unavoidable. If one or less times are used, distortion can be reduced if the workpiece is rolled in multiple passes. Therefore, it is necessary to increase the clearance of the mold.
3.6.2 Outer Corners of Angle Steel
Angle steel is an asymmetrical profile. When it is rolled, it is often distorted. Therefore, it is necessary for the support roller to provide an anti-distortion external force to the angle steel during the rolling process so that it can be corrected and the deformation can be reduced.
The adjustment of the support roller should be adjusted according to the deformation of the angle steel, and it is necessary to prevent the outward adjustment of the angle steel caused by excessive adjustment. Pre-bend is asymmetric, and roll is symmetrical.
Angle bending inside
The internal bending process of the angle steel is similar to the external bending of the angle steel. In the bending process, two directions will be distorted. Therefore, the support roller and the guide wheel are used to provide two anti-deformation external forces so that they can be corrected. Support rollers and guide wheels are adjusted according to the deformation of the angle steel.
Because the angle steel bends easily, the twisted deformation is easy to occur. Therefore, when the angle steel is bent, the diameter of the bent workpiece is larger than that of bending other profiles.
Adjust the side roller and feed the workpiece to the tail of the guide wheel. Adjust the guide wheel so that the workpiece can be rolled normally. The support roller will contact the flange end of the angle steel workpiece.
If the guide roller adjustment is too large, the workpiece will twist inward.
When the angle steel is bent inside, the support roller and the guide wheel device must be adjusted to the correct position, and then bent in the above manner until it is bent into a circle of a desired diameter.
3.6.3 I-beam, channel steel bending overview
I-beam, channel steel bending pre-bending end using asymmetrical bending, rolling system using symmetrical type, regardless of pre-rolling, or roll-rolling side roller not too much pressure, because it may cause the inner edge Twist deformation.
Reasonable lubrication of the machine is an effective measure to reduce the power consumption and improve the life of the machine. For this reason, a reasonable lubrication material must be selected and the necessary lubrication system must be established.
For artificial refueling, calcium-based grease is used. In the summer, No. 2 calcium-based grease is used. In winter, No. 1 calcium-based grease is used.
The user should establish a specific lubrication system according to the specific working system, load and operating conditions of the machine.
4.2.1 The lubrication points must be lubricated before the machine starts.
4.2.2 Machine Under continuous working conditions, gears are generally lubricated once every three months. All the rotating parts are made of oil-free bearings, which are generally refueled 6 to 10 months.
4.2.3 The entire lubrication system of the machine is cleaned once a year.
This machine is a fully hydraulically actuated open system. The rated power of the motor is 15KW. The rated working pressure is 16Mpa. The oil pump is a double gear pump CBF-F25/10. It is used for the oil motor rotation of the main drive system and the lifting and lowering of the auxiliary system cylinder. , There are no-load start, pressure adjustment, overload unloading, etc., through the shock-resistant table to observe the pressure adjustment range and pressure fluctuations.
The system is in the form of switch control. The condition of the solenoid valve is determined by the condition of the actuator (the lift of the auxiliary system cylinder, the positive and negative rotation of the main system motor), and the actuator is pressure-maintained by the pilot-operated check valve.
The fluid can be selected from 20# to 40# hydraulic oil according to the actual situation. The fluid is injected into the tank through the fine oil filter, and the liquid level should reach the upper limit of the oil level meter. After the initial trial run, due to the accumulation of oil in the fuel tanks and pipelines, the liquid level in the fuel tank drops. At this time, the oil in the tank should be replenished twice to ensure the normal operation of the system.
5.3.1 The effective volume of the fuel tank of this equipment is 200 liters. Select 20# to 40# ordinary hydraulic oil to be injected into the fuel tank after filtration by a fine oil filter, start the motor, check the direction of rotation is correct, and then start the operation test of each actuator. Several times, leaks, shocks, vibrations, etc. were discovered and stopped and checked in time. After the oil has fully entered the pipeline and the fuel tank, the tank should be replenished with oil again, so that the liquid level of the tank reaches the upper limit of the oil level.
5.3.2 When starting or stopping the oil pump, the relief valve shall be in an unloaded state. Once the set pressure of the relief valve is adjusted and determined, the lock nut of the relief valve shall be tightened and should not be changed frequently. After a period of no-load trial run, the gas in the pipeline is fully drained and the oil is fully filtered. After the actuators are moved smoothly and reliably, all filter elements are cleaned or replaced, and then a load test is performed.
5.3.3 The oil temperature of the system should not exceed 65°C. Consider the specific environmental conditions. If the machine is working in a hot environment, a higher viscosity hydraulic oil may be used to ensure a better working condition of the system and a longer time. The life of the product should minimize the contamination of the oil. Clean or replace the filter element regularly. Check the degree of deterioration of the oil every six months. If it exceeds the limit of use, replace it in time.
Method of exclusion
|A Suction filter blockage, oil suction tube internal diameter is small, oil temperature is too low, oil viscosity is too high to introduce the pump suction|
Replace or clean the oil filter, increase the diameter of the oil suction tube, warm the oil, and use hydraulic oil of suitable viscosity.
B The oil level is too low, the suction pipe leaks, and air enters the system to induce foam by other means.
Refuel, replace fittings, tubing or seals, exhaust the entire system
C. The transmission centerline is not correct, the coupling is loose, and the piping vibration causes mechanical vibration.
Right center, fastening screw, plus clamp
D oil pump motor is damaged
Replace pump or motor
E overflow valve is not stable
Insufficient or no pressure
A The oil pump does not turn to suck air
B oil pump damage
Replace oil pump
C. The pressure adjustment method is improper, there is something dirty in the overflow valve, and the poor sealing in the cylinder causes the leakage of the high-pressure side to the low pressure side.
Correctly adjust pressure, clean overflow valve, check replacement of damaged parts
D Coupling or motor is faulty
Check and replace
Abnormal pressure, flow or pressure fluctuations
A Pump Suction
See fault 1
B oil foam
C Mechanical vibration
D uneven oil pump
Repair or replace
E system mixed with air
Traffic is too small or no traffic
A Pump Suction
See fault 1
B oil foam
C oil pump wear
Repair or replace
See fault 2
D Severe leakage from the high pressure side to the low pressure side of the cylinder
E The oil pump is not rotating properly
Correct motor wiring
Oil temperature too high
A system pressure is too high
B Too little fluid
C pump is bad
|Replace oil pump|
This machine is powered by three-phase 380V, 50HZ AC power supply. The power line is composed of a 15kw three-phase asynchronous motor. The hydraulic system is driven by its drag. The control loop controls the transformer TC power supply. The roller displacements on both sides can be controlled by the photoelectric encoder. The displacement is converted to electricity, and the displacement is displayed on the digital display.
The specific operations of each function are as follows:
Close the power switch QF, and the power circuit has power before performing the following operations.
Close the key switch SA1 in the "ON" position, and the power indicator HL1 lights, indicating that the control power supply is powered.
Press the start button SB2 of the oil pump. After the oil pump starts the control of the control circuit, the motor M runs normally. At the same time, the indicator HL2 of the oil pump is on, indicating that the motor is starting normally, and pressing the oil pump stop button SB1 can stop Motor operation.
The jog and linkage of the main drive rotation can be realized by placing the selector switch SA2 at the “jog” and “linkage” positions respectively.
(1) Forward rotation: When the positive scroll button SB4 is pressed, the intermediate relay KA1 is pulled in and the relief valve YV0 and the electromagnetic directional valves YV15, YV1 are activated, and the motor can rotate in the forward direction.
(2) Reverse: Press the rewind button SB5, the intermediate relay KA2 pulls in, and the relief valve YV0 and solenoid reversing valves YV16, YV2 act, and the motor rotates in reverse.
Set the selection button SA3 to the “left” and “right” position, ie, the left and right rollers can be moved up and down respectively.
6.5.1 Left roller lift: set SA3 in “left” position, and the middle relay KA3 pulls in.
(1) Press the side roller up button SB6, the middle relay KA4 pulls in, the relief valve YV0 and the left lift valve YV7 act, and the left roller rises.
(2) Press the side roller down button SB7, the middle relay KA5 pulls in, the overflow valve YV0 and the left down valve YV8 act, and the left roller falls.
6.5.2 Right-side roller lifting: set SA3 to “right” position and intermediate relay KA3 is released.
(1) Press the side roller up button SB6, the middle relay KA4 pulls in, the relief valve YV0 and right
The lift valve YV10 moves and the right roller rises.
(2) Press the side roller down button SB7, the middle relay KA5 pulls in, the relief valve YV0 and right
Lower the valve YV9 and the right roller falls.
Place the selector button SA4 in the “Left” and “Right” positions, ie, the positive and negative rotations of the left and right support rollers, respectively.
6.6.1 Rotation of the left support roller: Place SA4 in the “left” position and the intermediate relay KA6 pulls in.
(1) Press the backup roller forward button SB8, the intermediate relay KA7 pulls in, the relief valve YV0 and the forward valve YV3 act, and the left backing roller rotates forward.
(2) Press the backup roller reversal button SB9, the intermediate relay KA8 pulls in, the relief valve YV0 and the reversing valve YV4 act, and the left support roller reverses.
6.6.2 Rotation of the right support roller: Place SA4 in the “right” position and the intermediate relay KA6 pulls in.
(1) Press the support roller forward button SB8, the intermediate relay KA7 pulls in, the relief valve YV0 and the positive valve YV14 act, and the right support roller rotates forward.
(2) Press the backup roller reversal button SB9, the intermediate relay KA8 pulls in, the relief valve YV0 and the reversing valve YV13 act, and the right support roller reverses.
Set the position of the selector button SA5 to “Left” and “Right”, that is, lift the left support roller and the right support roller separately.
6.7.1 Lift the left support roller, place SA5 in the “left” position, and pull the intermediate relay KA9.
(1) Press the support roller up button SB10, the intermediate relay KA10 pulls in, the relief valve YV0 and the left lift valve YV5 act, and the left support roller rises.
(2) Press the support roller lower button SB11, the intermediate relay KA11 pulls in, the relief valve YV0 and the left lift valve YV6 act, and the left support roller descends.
6.7.2 Right support roller lifting: Place SA5 in the “right” position and intermediate relay KA9 is released.
(1) Press the support roller up button SB10, the intermediate relay KA10 pulls in, the relief valve YV0 and the right lift valve YV11 act, and the right support roller rises.
(2) Press the back-up roller down button SB11, the intermediate relay KA11 pulls in, the relief valve YV0 and the right-down valve YV12 act, and the right back-up roller drops.
The displacement of both sides of the roller can be converted into electricity by the photoelectric encoder, and the displacement is displayed on the digital display.
After starting the machine, lower the rollers on both sides to the lower limit position of the cylinder, and the value on the display table will be cleared automatically. With this zero as the reference point, the two sides of the roller display table can display the roll displacements of the two sides respectively.
The installation of the machine requires that the shop floor be flat and levelled with oblique iron during installation. Its horizontal deviation should not exceed 0.2 mm per meter.
7.2.1 Preparation before Commissioning
(1) Check that all fastening joints are reliable.
(2) Check if the lubrication points and manual refueling points for each oil cup are sufficient.
(3) Check whether the circuit of the electronic control system is good and whether the grounding is proper.
After the check is normal, the test is performed by the operator who is familiar with the performance of the machine. The test procedure is as follows:
7.3.1 The idle operation test of the main drive and the lift drive is alternately performed in an intermittent manner. Every 15 minutes is a cycle. In each cycle, the running time ratio of the single run of the main drive and the lift drive is 2:1.
7.3.2 When making a single main drive operation, it is advisable to make the main roll mold contact with the side roll mold to make it turn. It takes half of the time for positive and negative rotation.
7.3.3 Lifting is repeated during a single auxiliary drive time.
7.4.1 The maximum temperature of the rolling bearing must not exceed 80°C.
7.4.2 The working mechanism of the machine and the operating mechanism shall be coordinated with each other, and the operation shall be flexible without any abnormal noise or jamming.
7.4.3 Electrical and lubrication systems are normal and reliable.
7.4.4 All joints of fasteners must not be loosened.
After the normal empty test, the load test can be carried out. The general procedure is as follows:
7.5.1 According to the relevant parameters of the profile specified in the basic parameter table, the end of the profile is pre-bent by the specified diameter after the straightening and derusting treatment.
7.5.2 According to the degree of proficiency of the operation, the circular workpieces are rolled into a given diameter.
7.6.1 The load test run shall meet the relevant performance requirements in the basic parameters.
7.6.2 During loading and load operation, the drive system shall be stable, free of impact and free of abnormal noise. The working system and operating system should be flexible, accurate, reliable, and the rollers must not swing. The temperature of each bearing must not exceed the above-mentioned regulations.
7.6.3 There shall be no slippage between the mould and the profile during the rolling process.
8.1.1 The operator should understand the structure and performance of the machine, be familiar with the operation method of the control system and the process of bending the workpiece, and strictly observe the safety operation.
8.1.2 Before starting and parking, all buttons of the electronic control system must be placed in the original position.
8.1.3 In the course of use, the lubrication conditions at each lubrication point should be checked frequently.
8.1.4 In the course of operation, if irregular noises, impacts, or swings are found, they should be stopped and overhauled immediately.
8.1.5 In the course of use, all transmission mechanisms and connection points should be inspected frequently to keep them free from any looseness and damage.
8.1.6 During the bending process, the profile must move along with the roller and slippage is not allowed.
8.1.7 During the rolling process, the side rollers must be raised and lowered before the main drive is stopped.
8.1.8 The unloading work is to remove the side rollers after the machine is parked.
Proper use and reasonable maintenance can extend the service life of the machine and reduce the cost of repair. The main maintenance work of the machine is as follows:
8.2.1 The machine must work under normal operation and lubrication, and strictly implement the lubrication system.
8.2.2 Make regular inspections and repairs.
8.2.3 All vulnerable parts, when excessive wear or loss of original performance requirements, should be promptly replaced. If parts are damaged, they should be repaired in time.
8.2.4 During use, attention should be paid to the temperature of each part, and the temperature of the rolling bearing must not exceed 80°C.
8.2.5 The electrical system shall be regularly inspected and dust-removed, and the failed components shall be promptly replaced. The machine tool shall be properly grounded.