- 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
Device Name:690Tons Hydraulic Power Unit
Power box: capacity 720L
Pump Model: CBQT-F532/F410-AFH6
Motor Model: Y200L-4-B5 30kW 1440rpm
Power Supply: 50Hz 380V
Control power supply: 50Hz 220V
Working pressure: 19-20MPa
Use hydraulic oil: L-HM46 anti-wear hydraulic oil
The system has five execution hydraulic cylinders, two lift cylinders on the upper roll, inverted oil cylinders and two pairs of material cylinders. The system uses dual high-pressure quantitative gear pumps as power devices, and superimposed hydraulic valves as control elements. The front pump powers the two lifting cylinders and the overturning cylinder of the upper roller. The rear pump provides power for two pairs of material cylinders. The pressure control circuit, synchronous circuit, and speed circuit constitute the entire hydraulic system. The system has the characteristics of simple pipeline layout, less leakage, convenient maintenance and debugging.
Plate Bending Machine After the machine body is installed, hang the hydraulic power box at the position specified in the foundation plan and connect the hose between the hydraulic power box and the Plate Bending Machine body. When connecting the hose, pay attention to whether the O-ring is installed correctly. The air filter on the hydraulic power box is filled with a sufficient quantity of the specified hydraulic oil, and the power cord is connected to the test vehicle.
The Plate Bending Machine uses stacked hydraulic valves. The installation sequence of each hydraulic valve is as follows:
A2 - Overturned cylinder upper chamber: Yv1, Yv3 - descending
B2 - Upside Down Cylinder: Yv2, Yv4 - Rise
A3 - upside down cylinder upper cylinder: Yv5 - upset
B3 - Upside Down Roller Cylinder Lower: Yv6 - Reset
A4——fixed side upper cylinder upper cavity
B4 - fixed side upper cylinder lower chamber
A6—The upper cavity of the material cylinder
1) System pressure adjustment:
a. Adjustment of roll down pressure on the system:
Press and hold down the button on both sides of the lower button of the hand button box to lower the upper roller and press the lower roller. When the upper roller presses the lower roller without falling, it continues to press the upper roller lower button. At this time, it adjusts the sequence of 12 valves. By reading the main system pressure gauge, the maximum reading is 19-20 MPa, and the adjustment can be repeated 2 or 3 times. , Adjust the lock nut of the 12 valve after locking. (Note that during the roll movement, adjust the level of the roll at any time)
b. Adjustment of upper roll up pressure
Press and hold the button on the button of the hand button box to raise the two sides of the upper roller. After rising to the position stop, continue pressing the upper roller up button to adjust two sequential superimposed overflow relief valves respectively, and watch the overturning side and the fixed side. The upper roller raises the pressure gauge to make it read 11.5~12.5 MPa, and repeats 2~3 times of adjustment. After adjusting, lock the lock nut of the sequence 22 valve.
c, tipping and reset pressure adjustment:
The tipping and return pressure is the upper roll lift pressure of 11.5 to 12.5 MPa.
d, the adjustment of the material pressure:
Press and hold the material up or down button on the console to continue pressing and holding the button. Then adjust the 25-stack superimposed overflow valve in the small valve group so that the material pressure gauge reads 7.5 to 8.5 MPa. Confirm and lock the adjustment nut.
2) Adjustment of the speed of the system:
a. Adjustment of the rise and fall speed of the upper roll:
The adjustment of the rising and falling speeds of the upper roller, the overturning side and the fixed side respectively adjusting the overlapped one-way throttle valve in the respective valve block, the inward rotating handle speed is reduced, and the outward rotating handle speed is increased. The rising and falling speeds of the upper roller should be adjusted repeatedly so that each time the two sides fall by 100mm, the speed difference is the minimum value.
b. Adjustment of tipping and reset speed:
For overturning and resetting speed adjustment, the overlapped one-way throttle valve 14 in the overturning cylinder stacking valve group should be adjusted. The inward rotating handle speed is decreased, and the outward rotating handle speed is increased. The adjustment of tipping and resetting speed should make the overturning frame move steadily with little impact. The time is about 20~60 seconds.
3) Adjustment and use of other hydraulic components:
a, pressure relay adjustment:
Pressure relay is when the upper cylinder of the upper roller has a certain pressure, the pressure relay sends an electric signal, so that the upper roller can not move horizontally at this time. When adjusting, the cover of the pressure relay should be opened to lower the upper roller. When the down pressure of the upper roller is 5.8~6.8 MPa, the stud inside the pressure relay is adjusted to make the pressure relay act and send an electrical signal.
b, pressure gauges and pressure gauges switch use:
The pressure gauge is mainly to display the pressure of the contents indicated by each sign. Each pressure gauge should return to zero when the coiling machine is not working (except for resetting the pressure gauge). If it does not reach zero, it should be replaced in time.
The pressure gauge switch is mainly used to control the opening and closing of the pressure gauge. The adjustment should minimize the swing of the pressure gauge pointer.
c. Use of air filter:
The air filter has two functions. First, clean air is introduced into the oil tank when the oil pump is working, and second, oil can be filtered when refueling. The air filter should be cleaned regularly and the time is based on the actual situation. (Air filter must be filtered when refueling)
d, the use of oil level oil thermometer:
The oil level oil temperature gauge is installed on the side of the oil tank to facilitate observation of the tank oil volume and oil temperature. When the oil level is lower than the minimum oil level during normal operation, hydraulic oil should be added. When the system temperature is higher than 65°C, cooling measures should be taken.
e. Use of the shut-off valve in the lower chamber of the oil cylinder:
This valve should be fully opened when the coiling machine works normally. Only when the coiler is maintained and does not work for a long time, the valve should be closed to prevent the coiler from tipping over.
1, routine inspection items:
Check the appearance of the hydraulic power box.
The amount of oil in the power box.
Leakage of the piping system.
Pumps, valves, cylinders, etc. leak.
Operating conditions of levers and switches.
Regular supplies of oil, grease, etc.
Drive warranty inspection.
Inspection of other bad places.
The above items are all performed with the hydraulic system stopped.
2, regular inspection items: 500 ~ 600 hours (60 ~ 75) days
Detailed inspection of the daily inspection items.Check the operation of the hydraulic system and operate each function at the maximum working pressure.
3, replace the working medium:raulic power box cover should be removed, and the oil pump filter and power box cavity cleaned.
The daily routine is to confirm the amount of power tank oil in accordance with the above items, and to supplement the insufficient parts, new oil should be replaced once a year. Before changing the oil, the hydraulic power box cover should be removed, and the oil pump filter and power box cavity cleaned.
Pump does not come out of oil
|Low oil pressure in the tank||Be careful not to allow the oil to fall to the underside of the oil level gauge during operation.|
Suction pipe obstructed oil absorption is not smooth
Clean the suction tube and all filters
Suction pipe sucks air
Seal the connector partially
The reverse direction of the oil pump
Change steering to meet requirements
Hydraulic oil viscosity is not suitable for local conditions
Use hydraulic oil suitable for the local area
Insufficient oil pump speed
Should reach the prescribed minimum speed
Oil in the air
|Investigate air mixing in and repair|
The pressure on the circuit does not go up
Because of the above reasons the pump does not come out of oil
Implement the above measures
The pressure set by the system has not reached the specified value
Resetting pressure with pressure gauge
Safety valve does not work
Remove to repair or replace new parts
Leakage inside valve and cylinder
The hydraulic circuit smoothly divides the area and checks each relatively independent part
Hydraulic valve does not work
Check each hydraulic valve and investigate the electrical circuit
Take the pump out for repair or replace it with a new one
Hydraulic system leaks
Check and repair
Damaged cylinder piston seal material
Repair cylinder replacement seal
Inverted valve commutation fault
Check and repair shuttle valve
Is there any dust in the control system?
Suction tube, filter blocked
|Sweep clean, wash filter|
Cylinder pressure cannot hold
Damaged cylinder seal material
Repair cylinder replacement seal
Superimposed pilot-operated check valve leak in the circuit
Clean or replace the stacked pilot operated check valve
In-circuit one-way throttle check valve oil leakage
Clean or replace stacked check valve
System valve block leakage
Check valve block and repair
Pressure gauge or pressure gauge switch leaks on the circuit
Replace seal or change parts
Oil pump noise abnormal
|Oil pump inlet pipe into the air|
Combined with grease seal, if the sound becomes smaller, tighten or replace the seal
Air from the pump side
Around the shaft with grease seal, if the sound becomes smaller, replace the seal
Loose pump and motor bolts
Tighten the bolt
Motor and oil pump do not care
Check and repair
Overflow valve vibration
Investigate whether there is air entering
The oil is too thick
Use with local suitable hydraulic oil
Oil pump suction pipe filter blocked
|Cleaning or changing parts|
The direction of rotation of the oil pump is reversed
Correct the direction of rotation
There are air bubbles in the oil
Investigate the presence of moisture in the return pipe
Oil level below baseline
Add oil to the baseline
Beyond the prescribed rotation pressure
Adjust the rotation number and pressure
Slow cylinder operation
Damage to tubing and pipe seals
Perform single-piece test run and replace the sealing element
The specified amount of oil has not flowed from the pump
Refer to the oil pump failure, as a benchmark to repair
Improper adjustment of speed control valve
Large reaction force to the cylinder
|Increase the size of the tube or increase the pressure on the system|
6-1-1, unbalanced lifting is strictly prohibited so as not to damage the machine;
6-1-2. It is forbidden to collide the machined surface of the machine parts during lifting.
6-1-3. During the transportation, the machine must be fastened to avoid damage to the machine and rain and rust prevention measures must be taken.
When the machine is not used for a long period of time, the upper roller must be brought into contact with the lower roller, the power supply is turned off, the machine is cleaned, and moisture-proof, rust-proof and dust-proof measures are taken.
Before installing the machine, check the quantity of each component and standard part according to the packing list, and determine the installation position of the parts according to the assembly drawing. Check the pouring of the foundation according to the requirements of the foundation drawing.
The machine shall be installed on a sturdy foundation in accordance with the requirements of the foundation plan. The level shall be adjusted, the anchor bolts shall be fastened, and then the wiring of the electrical control part and the piping installation of the hydraulic part shall be carried out.
After the installation of the machine is completed, it is necessary to further check the tightening status of each joint of the machine and whether each moving part is flexible, whether the wiring and grounding line of the electrical control part is normal, whether the hydraulic pipe connection is in good condition and whether the lubrication points are full of oil. Wait for the test vehicle.