- Ⅰ. Application
- Ⅱ. Main technical data
- Ⅲ. Structure and main parts
- Ⅳ. Electrical system
- 4-1. Electrical parameters
- 4-2. Electrical Principle
- 4-3. Operation of the Machine
- 4-4. Installation and Maintenance of the Machine
- 4-5. maintenance
- 4-6. Common Troubleshooting Methods
- 4-6. Common Troubleshooting Methods
- Ⅴ. Hydraulic system
- 5-1. The main parameters
- 5-2. System Overview
- 5-3. System Installation
- 5-4. System Adjustment
- 5-5. Maintenance and Inspection
- 5-6. Common Faults and Handling Methods
- Ⅵ. Lifting and storage of the machine
- 6-1. Precautions for Machine Lifting
- 6-2. Machine Precautions
- Ⅶ. Installation of the machine
- 7-1. Check before installation
- 7-2. Installation of the machine
- 7-3. Installation inspection of the machine
- Ⅷ. Instructions and rolling process
- 8-1. Preparations before Operation
- 8-2. Precautions during Operation
- 8-3. Ready to Operate
- 8-4. Operation
- 8-5. Safety Devices
- Ⅸ. Rolling Process
- Ⅹ. Daily inspection of the machine
Roller motor M1: YZR315M-10 75kW
Mobile Motor M2: YEJ160L-4 15kW
Roller motor M3: YEJ132M-6 4kW
Pump Motor M4: Y200L-4 30kW
Programmable Controller: OMRON CPM1A-40CDR
The W11S-60×3200 Three Roller Plate Rolling Machine is based on a PLC programmable controller, equipped with a highly reliable digital display, and a displacement sensor to form a reliable, real-time control system.
(1) PLC programmable controller: W11S-60 × 3200 Three Roller Plate Rolling Machine selected PLC is OMRON CPM1A-40 CDR programmer, composed of CPM1A-40CDR and CPM1A-20ERR1.
(2) Digital display and control system: The system uses the digital display as the core, and is equipped with the corresponding displacement sensor interface. It forms a reliable and real-time control system with the PLC to realize the TNC control of the machine tool.
(3) various movements of machine tools
a, positive and negative rotation of the lower roller motor
The lower roller motor is forward and reversed by the contactors KM11 and KM12. The frequency sensitive rheostat is connected to the rotor circuit to realize the start of the series-frequency sensitive rheostat of the motor rotor, thereby reducing the starting current of the motor. The input modules 00006 and 0007 are turned on, and the CPU and internal programs are controlled so that the 1000 and 1001 output modules are driven to control KA2 and KA3. The KA2 and KA3 are used to control the connection of KM11 and KM12. Since the KM11 and KM12 are connected, the KM10 will be turned on by the time delay output point 1002 of the PLC internal time relay to achieve the time-delay cut-off of the frequency-sensitive varistor.
b. The roller motor moves back and forth
The horizontal movement of the upper roller is controlled by KM21, KM22 and M2 realizes the forward and backward movement of the upper roller, and the input modules 004 and 0005 are turned on to realize the control of the output points 1003 and 1004 of the KM21 and KM22.
c. Roller motor lift
The contactors KM31 and KM32 work separately, so that the M3 drives the lifting and lowering movement of the idler, which is realized by the input points 0010 and 0011 during the adjustment. Output points 1005, 1006 control KM31, KM32.
d, the lifting of the upper roller
The lift of the upper roller is driven by the M4 motor and the hydraulic pump is controlled by the solenoid valve. First press the "oil pump work" button to make the oil pump motor work.
When the upper roller is required to rise, the input point 0000 is turned on, and through the process of the internal program of the CPU, the control output points 1201, 1203, and 1205 enable the KA6, KA8, and KA10 relay operation control YV2, YV4, and YV6 solenoid valves.
Roll on the drop
When it is necessary to lower the roll, press the down button 00001 point is activated, control the output point 1200, 1202 so that the solenoid valve KA5, KA7 relay operation control YV1, YV3 get electricity work.
When the values of the data on both sides of the upper roller's descending displacement are not equal, a single descending displacement adjustment can be made by "falling side down" 0002 and "fixed side down" 0003. Output point: (fall side down) 1200; (fixed side down) 1202 corresponding solenoid valve (fall side down) YV1; (fixed side down) YV3.
The above actions (upper roller, idler lift, lower roller action) can only be performed when the "Trocket Rack Reset" indicator is on.
e, flipping action
When rolling up the plate, the tilting frame needs to be tipped over to remove the workpiece. Before the tipping over, the upper roller should be moved to the center and raised to the highest position. SQ7 and SQ8 act at the same time, and the “upper roller on the center” indicator light is on, and the “overturning frame overturn” 0102 point is activated. The output module 1201, 1203, 1204 turn on to make KA6, KA8, KA9 relay action control YV2, YV4, YV5 get electric action, when the tilting frame is tilted to the limit position, the corresponding limit switch SQ5 cut off this circuit. According to the "overturn stand reset" 0103 points are energized, the output modules 1201, 1203, 1205 are turned on so that KA6, KA8, KA10 relay action control YV2, YV4, YV6 get electric action. When the tilting frame is reset back to its original position, the limit switch SQ6 mounted on the side of the overturning cylinder is used for detection. After a delay of 3 seconds, the indicator of the "overturning frame reset" is on, and the reset circuit electromagnetic valve is cut off.
f, the material action
After the sheet is fed into the sheet, the sheet is to be proofed against the material baffle. Press the "Material Up" to control the output module 1206 KA11 relay to control the electric action by the input module 0100.
"Material drop": Input module 0101 controls output module 1207 to control the action of KA12 relay.
(4) Displacement indication of each movement
The horizontal movement of the upper roller is detected by the horizontal movement fixed rack side displacement sensor for horizontal movement displacement detection, through the display of a digital display on the operator's desk, when the upper roller is located in the center line of the two lower rollers, the upper roller is horizontally moved to display the X coordinate display. For "zero", the "+" value is displayed when the upper roller moves toward the front of the machine, and the "-" value is displayed when the upper roller moves toward the back of the machine.
The vertical movement of the upper roller is detected by lifting and lowering the upper roller of the two-cylinder-side displacement sensor. When the upper roller is at the upper end (the uppermost position of the two cylinders), the two coordinates are displayed as “zero”. When the upper roller moves down, both brackets are marked with "+".
Roller lift is detected by the roller holder and chassis side displacement sensor. When the idler just touches the bottom roller and three idlers start to rotate at the same time, the value of H should be “zero”, and it is positive when it rises. The value is displayed, showing a negative value when dropped.(5) Various protectionsEach motor has a corresponding circuit breaker for short circuit and overload protection and corresponding thermal relay for overload protection.There is a corresponding limit switch for tripping and resetting. There is a limit protection. After the tripping unit is reset, it will delay 3 seconds to fully reset.The horizontal movement motor has two limit switches for the extreme protection of the corresponding actions.The roller lifting motor has two limit switches for the ultimate protection of the corresponding actions.
Roller lift is detected by the roller holder and chassis side displacement sensor. When the idler just touches the bottom roller and three idlers start to rotate at the same time, the value of H should be “zero”, and it is positive when it rises. The value is displayed, showing a negative value when dropped.
(5) Various protections
Each motor has a corresponding circuit breaker for short circuit and overload protection and corresponding thermal relay for overload protection.
There is a corresponding limit switch for tripping and resetting. There is a limit protection. After the tripping unit is reset, it will delay 3 seconds to fully reset.
The horizontal movement motor has two limit switches for the extreme protection of the corresponding actions.
The roller lifting motor has two limit switches for the ultimate protection of the corresponding actions.
The main power circuit breaker adopts shunt release type and can be remotely controlled through the “emergency stop” button.
(6) Various interlocks
The upper roller rises to the limit position, and when it is in the central position, the “upper roller on the center” indicator light is on, and the tilting frame can be turned over, controlled by SQ7 and SQ8.
After the tilting frame is fully reset, the "overturning frame reset" indicator light is on, and the upper roller, the idler roll up and down, the upper roller horizontally moving, and the lower roller motor forward and reverse can be moved by the SQ6 and the corresponding time delay (in the PLC). For restrictions.
When the upper roller is in the upper position, that is, when the upper roller tail contacts the balance beam, the “falling side down” cannot be lowered independently, and the upper roller cannot be moved horizontally, which is limited by the upper limit switch of the upper roller of the SQ7.
When the upper and lower roller pressures are higher than 1/3 PN, the upper roller cannot be moved horizontally, and the idler roller cannot be raised or lowered. This is limited by the SP pressure relay.
(7) Top roller TNC (rotary button in the "TNC ON" position)
When the "upper roll down" is pressed, the upper roll is automatically stopped when it drops to No. 1 (Y2). At the same time, when the "Flip side down" or "Fixed side down" is pressed simultaneously, the upper roller drops to No. 2 (Y3) and automatically stops. When the “Scroll up” button is pressed, the upper roller automatically stops when it moves to +X, and when the “upper roller moves backward” button is pressed, the upper roller moves to -X and stops automatically.
Each movement of the moving button box is performed by jogging. When it is required to act on the upper and lower rollers, the knob is rotated to the “linkage” position to operate the buttons of the console.
(9) Each movement instruction
The corresponding coordinates are displayed in the digital display in each movement of the machine tool to monitor the current position of each action. At the same time in the corresponding indicator light for certain actions to restraint see (6) various interlocks.
This machine uses the electric control cabinet as the main centralized control component, together with the operation table and the digital display inspection system, can realize the adjustment of the rolled plate and the upper roll TNC process. For the convenience of operation and the mobility during operation, the movable button can be used. Box operation.
Close the air switches in the cabinet to provide power for each motor and control circuit. Close the electric cabinet door and close the air switch on the right side of the electric cabinet to provide the main power for the machine tool. At this point the power indicator light, according to the "control work" corresponding indicator light, at this time can be the machine tool control loop work, such as contactors, solenoid valves and so on.
(1) The function of each button is as follows:
TNC ON OFF-- -- When turning on the ON position, the upper roller can respond to the automatic control of each desired positioning point.
Jog, linkage - jog: jog operation of each movement of the upper roll and lower roll;
Linkage: The upper roller and the lower roller move in tandem and stop working through the corresponding stop button.
The buttons on the portable button box are jog execution buttons.
Tilting stand upside down - When the upper roll is in the upper center, the tipping stand can be tipped over to remove the workpiece.
Trestle Stand Stopping - The Trestle Stand can be parked in any position during the operation of the tilting stand.
Traprest reset - return the tripping frame to its original position.
The upper roll rises - the cylinders on both sides of the upper roll rise at the same time.
The upper roll is lowered - the cylinders on both sides of the upper roll are simultaneously lowered, responding to Yg2, Yf2 when "TNC". *
Flip side down - The cylinder on the overturn side of the upper roll falls alone, responding to Yf3 when "TNC". *
Fixed side down - the cylinder on the fixed side of the upper roll is lowered individually, and responds to Yg3 when "TNC". *
Upper roll forward - The upper roll stand moves toward the front of the machine. "TNC" responds to +X. *
The upper roll moves back - the upper roll stand moves toward the back of the machine. "TNC" responds to -X. *
The upper roller stops - stops the upper roller from moving up and down in the "linkage" position.
The lower roll rotates in the forward direction - the lower roll runs in the forward direction.
The lower roll reversed - the lower roll reversed.
Lower roller stop - Stops rotation of the lower roller in the "linked" position.
Roller rises - the idler rack rises H. *
The idler drops - the idler rack descends H. *
The material rises - the material block rises. *
Decrease of material - drop of material stopper
Operator Station Button Box--Dial to the corresponding position, only the corresponding operation can be operated. When dialing the console, please push the button box to the OFF position.
Note: When responding to Yg3, this button is pressed. When the upper roller moves down to Yg3, it will stop automatically.
(2) Digital display operation
Digital display setting operation:
For details, refer to the instruction manual P14 and P33 of the digital display. Initial setting method: 5-2-5 Set the comparison value of the relay output.
Note: 1No.1 must be less than No.2, No.2 must be less than No.3, No.3 is unnecessary data on this device, but it must be set and the data should be greater than No.2.
2 The upper roller horizontal movement coordinate No. 1 is set to a fixed value, No. 2 is set to a positive value, No. 3 is set to an upright value, and is greater than No. 2
Connect the wiring of each motor, solenoid valve, console, and digital display according to the electrical external wiring diagram, and ensure that each live body is grounded reliably.
Check the insulation resistance of the motor within the allowable range, and adjust the current of each thermal relay to be 1.05 times the rated current of the motor. . When it is confirmed that it is in good condition, check the operation of the machine.
Check the direction of the motor and the motor current is within the allowable range. Limit position and accuracy of each limit switch.
In the TNC state, the accuracy of the operation setting bit for each operation of no-load test operation is accurate.
Check regularly that the insulation resistance of each motor is within the allowable range.Periodically check the reliability of the wiring in the cabinet and console.
Regularly check the correct flexibility of each indicator, solenoid valve, and contactor.
PLC maintenance: Check the input loop. When the input loop control element (button, digital display output contact, etc.) is closed, the corresponding contact work indicator is on, otherwise check the input circuit components and connection.
When the output contact is working, the corresponding working indicator is on. At the same time, the corresponding output element (solenoid valve, contactor, etc.) is switched on. Otherwise, the output circuit element and wiring are checked.
RUN (green) The CPU unit is lit during normal operation
ERR/ALM (red) Blinks when there is a non-fatal error. When the battery life span is on, the battery should be replaced within one week.
COMM (yellow) Flashes each time the CPU Unit communicates with an external deviceThe “fault indication” light is the motor overload indication, the next roller is overdriven and the motor is overloaded, and the corresponding thermal relay is activated. The indicator light flashes for 1 second; the upper roller moves horizontally and the motor is overloaded, and the corresponding thermal relay moves. The indicator light flashes for 2 seconds. The roller lift motor is overloaded and the corresponding thermal relay is activated. The indicator light flashes for 3 seconds. Check the cause of motor overload. After confirming that the fault has been cleared, press the reset button on the thermal relay to resume the machine tool operation.
Note: For the normal operation of the coiling machine, if it is necessary to perform initial welding of the workpiece on the machine body, be sure to connect the welding machine's grounding wire to the workpiece. Do not use the body as a transitional ground wire to avoid damaging the digital display system with large currents.