operation instruction
instruction
Unit model:
Factory number:
Manufacturing date: October, 2000.
Tel: 86-757-81162186.
Fax: 86-757-81162189.
E-mail: fsbaiguan@ 163.com
catalogue
I. Introduction
Two. Uses and characteristics
Three. Structural characteristics and functional maintenance of molding machine
Four. Hoisting and installation
Verb (abbreviation of verb) model classification and composition
Structure and main forming parameters of intransitive verb unit
Seven. Molding adjustment
Eight. Common faults of pipe making machine and their inspection and elimination methods ..............................................................................................................................................................
Nine. Warranty regulations and certificates of conformity .....................................................................................................................................................................
X. mechanical pictures 18
I. Introduction
Guanbai brand welded pipe machinery. die
Revolution of stainless steel welded pipe technology
Defects such as strain, wrinkling, nail grain, fish scale grain, mechanical grain, handle, uneven forming surface of rectangular pipe, sharp corner, concave corner, round pipe out of round and square pipe often appear in the production process of stainless steel welded pipe. Over the years, these defects have been puzzling people in the industry, and they are also the most difficult problems to overcome in the mold industry. After years of painstaking research and practice, Guanbairen finally produced high-quality mechanical molds of Guanbai brand, which solved these problems and brought good news to people in the industry.
Special recommendation: In view of the phenomenon that the hardness of 20 1 steel plate on the market is excellent and the polished pipe is not round, Guanbai brand die has been produced after more than half a year's careful research, which has put an end to this phenomenon and brought good news to the vast number of 20 1 users.
"Guanbai" brand mold-a more reasonable molding principle
Unconventional hardness of molding surface
Therefore, it not only solves the defects in pipe making, but also prolongs its service life many times compared with ordinary dies. The hardness of Guanbai brand die material Cr 12MoV can reach 61~ 63 HRC. According to theoretical calculation, "Guanbai" brand mold does not need maintenance for three years, which greatly reduces the troubles and maintenance costs of users and wins wide acclaim from users.
Foshan Guanbai Technology Co., Ltd. is a high-tech enterprise. Over the years, we have devoted ourselves to the research, development, production and sales at home and abroad of stainless steel welded pipe molds, stainless steel decorative (industrial, composite) welded pipe machines, polishing machines, flat-mouth machines, embossing machines, internal leveling devices, online bright solution annealing equipment and other supporting equipment for stainless steel production, and have undertaken cooperation with foreign OEM/ODM orders.
"Guanbai" series products are improved by more than 20 senior designers and engineers for many years. "Guanbai" brand welded pipe (manufacturing) machine adopts ultra-thin design and heavy equipment, the thinnest one can be welded to 0. 15mm, and the thickest industrial welded pipe machine can be welded to 10.00mm, ranking first in the industry. The "Baiguan" die solved the problems of strain, wrinkling, fingerprint, mechanical grain, diagonal angle and concave angle in the process of pipe making, and achieved zero maintenance rate after the die was put into use.
Guan Bairen adheres to the corporate philosophy of "winning with technology and pursuing perfection" and pioneering with "scientific, rigorous and innovative" working methods; Have keen market insight, hunt for the latest information in the industry, take market demand as the guide and take customers as the center; To provide customers with high-quality and reliable products with first-class products and first-class services, Guan Bai warmly welcomes people from all walks of life to join us and create a better future!
Two. Uses and characteristics
I. Overview:
Welcome to use Guanbai brand stainless steel pipe welding machine. Our company is one of the largest professional manufacturers of stainless steel welded pipe machine, stainless steel welded pipe mold, polishing machine, composite pipe machine and other supporting equipment in Foshan. After years of unremitting efforts and careful research, Guanbairen produced Guanbai brand pipe-making machine and mould, which solved the common phenomena of strain, wrinkling and nail lines in pipe-making, thus making Lin Bao brand pipe-making machine and mould occupy an important position in the market. With the work style of "science, preciseness and innovation", Guan Bairen pursues the enterprise concept of "technology wins and strives for perfection" and keeps making progress. Explore the latest information of the industry with a keen sense of market smell, take market demand as the guide, take customers as the center, make greater contributions to the development and prosperity of the stainless steel industry with first-class products and first-class services, and warmly welcome people from all walks of life to inquire and negotiate business.
Two. Uses and characteristics
BG series industrial pipe-making machines are mainly used in the continuous forming process of industrial stainless steel profiles (round pipes, square pipes, special-shaped pipes and composite pipes), which are produced through unreeling, cleaning, forming, argon arc welding, weld grinding, internal leveling, sizing straightening, bright solution treatment, sizing straightening and cutting to length. The process is characterized by continuous production, high efficiency, less material waste and low production cost.
The production line of BG series pipe making machine is mainly composed of four parts: feeding frame, main machine, cutting machine and finished product frame.
The main machine consists of a lathe bed, a feeding guide roller, a flat roller bracket, a weld grinding head, a straightening frame, a worm gear reducer, a main driving motor, an electric control system and a water cooling system.
3. Structural characteristics and maintenance of molding machine
First, the structural characteristics:
1. The electrical equipment of this unit adopts frequency conversion speed regulation.
2. Frequency conversion speed regulation technology is adopted, which has high speed regulation sensitivity, smooth speed regulation, low noise and less power loss.
3. The forming machine and sizing machine are driven by a motor, which has compact structure, simple maintenance and convenient lifting and installation operation.
4. The transmission adopts cross universal joint coupling, which has the advantages of large transmission torque, long service life, neatness, beauty and portability.
5. The cross frame is a transmission frame, which is driven by a worm gear box and a coupling. There is a 4-speed gearbox (1 reverse gear) between the worm gear box and the motor, which makes the operation of the unit more convenient and the rolling movement more stable.
6. The horizontal frame is a two-roll side roll support. When the roller needs to be replaced, it is simple and convenient to loosen the fixing bolt of the outer bracket, pull out the outer bracket and replace the roller on the side. The two sides of the frame are adjusted separately, which is flexible, convenient and accurate.
7. The vertical roller can be adjusted in the horizontal direction or in the vertical direction simultaneously or independently in the machine base, which is more convenient. Roller bearings are used.
8. The feeding frame adopts a rotatable parallel four-bar cantilever double drum mechanism, and the connecting tape can be wound during the working process of the unit, thus reducing the preparation time and enabling the unit to continuously produce without looper device.
9. The included angle between the axes of the first two weld grinders and the rolling center line is+/-45, which can be adjusted. The weld is polished from two staggered directions, and the axis of the next weld grinder forms an included angle of 90 degrees with the rolling center line, so the polishing effect is better.
Two. Maintenance inspection
Due to the different frequency of use and environmental conditions, the maintenance and inspection contents of the molding machine are also different (see table 1). As can be seen from the table 1, the focus of maintenance inspection is to check regularly and prepare enough consumables to ensure normal operation and production.
Table 1: Maintenance and Inspection Standards for Molding Machines
Inspection site
Inspection cycle
Maintenance inspection content
Driving device, bearing, etc.
1/ day
Oil supply state of driving device
Oil supply status of roller bearing parts
cardan joint
2-3 times/time
Grease supply status of universal joint head
Grease supply point
Week/time
Month/time
(1) Oil quantity in gearbox
(2) the amount of oil in the worm gear box
(3) Supply status of cooling system
(4) Check the cleanliness and emulsification of the oil in the oil tank, the cleanliness and odor of the coolant (if there is any abnormality, check the following places and change the oil).
1. Is the oil seal damaged?
2. Is the gear damaged?
3. Is there any leakage in the pipeline?
Rolling drum
Month/time
(1) Check around the drum.
1. Check the damage of the roller locking screw.
2. Damage and wear on the surface of the roller shaft
Roller drive device
Year/time
(2) Check the curvature of the roller shaft
Roller drive device
Week/time
Bearing temperature rise
Roller drive device
2-3 times a week
Wear of worm gear
Roller drive device
Year/time
bearing wear
4. Lifting and installation
The molding machine needs to be lifted and transported to the designated place by crane, forklift and other lifting equipment or rolling pin. If a crane is used, the crane cable must bear more than 5 tons of weight. When lifting, just hang the steel cable on the four hooks. When lifting, be careful not to let the wire rope directly contact the equipment, so as not to damage the paint and parts.
In order to make the molding machine work stably and accurately, the molding machine must be placed on a solid foundation. Before anchor bolts, the molding machine must be adjusted in vertical and horizontal directions with a spirit level, so that the workbench of the molding machine is horizontal, and the flat rollers of the front and rear machine beds are on the same straight line, the horizontal error of the workbench is not more than 0.04mm, and the position error of the flat rollers is not more than 0.0 1 mm ... After the adjustment meets the specifications, the inclined iron is padded, the anchor bolts are tightened evenly, and then concrete is poured around the frame for fixation.
Verb (abbreviation of verb) Classification and composition of aircraft types
A, type classification:
At present, the varieties of stainless steel industrial welded pipes produced by our company are Ф 30, Ф 40, Ф 50, Ф 60, Ф 80, Ф 90, Ф100, and can be designed and produced according to customer requirements.
2. The composition of the unit:
1. Unloading rack: double-station bearing seat design, rotatable, equipped with brake wheel.
type
Inner hole size of steel strip
Outside diameter dimension of steel strip
Maximum bearing capacity of steel strip
Type Ф 30
Ф 330-510mm
Ф1700 mm or less
2.5T
Ф 40 type, small 40 type
Ф 330-520mm
Ф1800 mm or less
3.0T
Type Ф 50 (single station)
Ф 410-530mm
Ф1800 mm or less
3.5T
Type Ф 60 (single station)
Ф 410-530mm
Ф/kloc-below 0/850mm
5T
Type Ф 90 (single station)
Ф 420-540mm
Ф/kloc-below 0/850mm
8T
2. Main machine part: It consists of forming group, grinding group and sizing part.
(1) molding group; It is composed of 6 groups of horizontal archways and 9 groups of standing signs (40, 50 and 60 units) (arrangement: VHVHVHVVVHVHVHVVH). Among them, the rear 1 erection clamp and two sets of horizontal clamps are welding sections.
(2) Grinding group: consisting of three grinding heads (the motor adopts 3KW two-stage motor). The grinding head is designed with double columns and guide rails, and the base can rotate at multiple angles to grind the weld (VV).
(3) Correction section: It consists of four groups of horizontal archways, four groups of vertical slabs (30, 40 and 50 units) and two correction frames (arrangement: Hhvhvhth1TH2V).
3. Cutting table: automatic cutting with metal saw, 3-7.5KW two-stage motor.
4. Unloading rack: automatic unloading is controlled by air cylinder, with fixed size and length: 3 ~ 8.
6. Unit structure and main molding parameters
1. Pipe making range of pipe making machine:
type
wall thickness
circular tube
Square/distance tube
Type Ф 30
0.3 ~ 2.0 mm
Ф 5 ~ Ф 25mm
F 10* 10-20*20
Type Ф 40
0.3 ~ 3.0 mm
Ф12 ~ Ф 50.8 mm
F 10X 10-F40X40
Type Ф 50
0.4 ~ 3.5 mm
Ф 31.8 ~ Ф 76mm
F25X25-F75X45
Type Ф 60
0.6 ~ 4.5 mm
Ф 50.8 ~ Ф114 mm
F38X38-F89X89
Type Ф100
0.9 ~ 8.0 mm
Ф129 ~ Ф 219mm
F90X90-F 180X 180
2. Sizing length: 3 ~ 8m. Dimensional accuracy: < < 8mm.
3. Pipe making machine speed: 3 ~ 18m/min
4. Main engine power: double motors
Type Ф 30: 4KW
Type Ф 40: 5.5kW.
Type Ф 50: 7.5kW.
Type Ф 60: 1 1KW
Type Ф 70:18.5kW.
Type Ф 80: 22KW
Type Ф 90: 35KW
Type Ф100: 37KW
Note: this unit is equipped with two kinds of electrical appliances, one is AC electromagnetic speed regulation and the other is frequency conversion speed regulation.
5. Motor power of grinding head: 3kW (type 30, 40, 50, 60 and 70) and 4kW (type 80, 90 and 100).
6. Motor power of cutting machine: 3kW (models 30, 40, 50 and 60) and 5.5kW (models 70, 80, 90, 100).
7. Overall dimensions of main engine: length (mm) * width (mm) * height (mm)
Type Ф 30: 5300 * 1000 * 1750 Type Ф 40: 7300 *10 *1750.
Type Ф 50: 8700 *1210 *1800Ф 60:12000 *1320 */800.
8. Main engine weight: Ф 30 type: about 5500 kg; Type Ф 40: about 6500Kg.
Type Ф 50: about 7500kgф60 Type Ф 60: about 10000Kg.
Figure1:Electrical wiring diagram of 30 ~ 40 motor and 50 ~ 60 motor.
Figure 2: Circuit diagram of 50. /.60 Machine control
Figure 3: Electrical wiring diagram of cutting machine
Seven. Molding adjustment
The strip is molded by a molding machine, and it is required to be molded into a pipe with good quality, which is supplied to a welding machine to be welded into a round pipe. The forming quality directly affects the welding quality. Under certain equipment conditions, correct adjustment operation is the decisive factor of molding quality.
1. Basic requirements for molding quality include:
A, the formed tube blank has a correct circular tube shape;
B. The pipe size meets the pass design requirements;
C. Both sides of the pipe seam are straight, and there is no welding between high and low towers;
D. the pipe joint is not twisted;
E. There are no waves and protrusions on the two heald edges of the pipe seam;
F adjust the opening angle to the required angle (2 ~ 6 degrees)
G the tube blank has no surface defects such as crushing and serious scratch.
2. Adjustment and assembly of molding machine
① Leveling adjustment
A. Press-down adjustment: Press-down means that the bearing is driven to rise and fall by rotating the press-down nut on the bearing seat, and the two bearing seats are adjusted independently.
B. Axial adjustment
3. One end of the lower bearing is provided with a locating surface for locating the position of the lower roller. A set of nuts are installed at both ends of the upper roller shaft, and the upper roller is moved by rotating the nuts to achieve the purpose of axial adjustment.
(2) Adjustment of the fixed roller
A. Lateral adjustment of vertical roller shaft: adjust the lateral position of vertical roller shaft with two sets of screw pairs, and the other set of screw pairs synchronously adjust the opening and closing of two vertical rollers.
B height adjustment of the vertical roller shaft: loosen the lock nut between the vertical roller shaft and the slider, and rotate the vertical roller shaft to raise or lower the vertical roller shaft. Adjust the knob and lock the nut to adjust the two vertical rollers independently.
4. Basic principles of molding adjustment
A. Correctly adjust the bottom line of the formed tube blank
The bottom line of the tube blank is guaranteed by the roller and the equipment itself.
B, correctly adjust the hole center of each frame in a straight line.
The lower roller is positioned with the lower roller shaft plane through the positioning sleeve, and the upper roller is aligned and positioned through the lower roller positioning plane.
C. correctly adjust the horizontal position of the drum.
Check horizontally whether the center line of the upper roller of the horizontal roller of each frame is horizontal, and whether there is an inclination phenomenon that one end is high and the other end is low, and adjust the level through the pressing device.
D. Adjust the rollers of each frame correctly.
According to the pass and process specification, adjust the horizontal and vertical roll gap to meet the needs. The roll gap is too large, the deformation is insufficient, and the steel strip slides and twists left and right in the pass. If the roll gap is too small, the forming load will increase and the machine body will be damaged.
E. Check whether the diameter, pass size and shape of the roller conform to the regulations, and check whether the surface of the roller is smooth and free from defects.
F. The roller shall be fastened after installation and fixation.
The drum should be installed and fixed firmly, and axial string movement and radial jump are not allowed. Check whether the bearing is damaged or loose, whether the frame is firmly fixed on the bed, and whether the connection between the cover and the frame is firm.
G. is the drum rotating flexibly?
Check whether the bearing is in good condition, whether the clearance is appropriate and whether the drum rotates flexibly.
5. Inspection during normal production
Check frequently during normal production: whether the motor, gearbox and worm gear box are overheated, whether they operate normally, whether the universal joint and coupling are normal and damaged, whether the emulsion concentration is appropriate, whether the rollers of each frame are fully cooled, whether the tube blank moves and whether the molding quality is good, and adjust and eliminate the defects and faults generated in the molding process at any time.
6. Forming defects and elimination
The common defects of molded tube blank are dislocation, distortion, bulging, indentation or abrasion.
Eight. Common faults of pipe making machine and their elimination methods
breakdown
probable cause
exclusive method
1. The main motor trips.
1. Overload and motor heating
2. The relay current control is too small.
3. The motor outlet is poorly ventilated.
4. The gear is too high
5. Line aging and leakage
1. Check the rotation of the machine to see if any parts are stuck and the oil level in the gearbox is too high or there is no oil.
2. Open the electric box and increase the current of the motor protection relay.
3. Check the air outlet of the motor to see if there are sundries blocking the air outlet.
4. When making large and thick pipes, the gear should be set to 1 or 2, or even reverse.
5. Check the wiring. If there is any problem, please replace it.
2. The high-speed box of the grinding head is heated, and the grinding head vibrates greatly.
1. Oil cut-off due to long-term operation.
2. Installation eccentricity of impeller
3. Bending of grinding shaft
4. The adjusting bolt of the grinding head frame is not tightened.
5. The motor bearing clearance is large or the blades are damaged.
1. After cleaning with clean diesel oil.
Add No.20 engine oil
2. Check the thousand-page wheel to see if the inner hole is too large.
3. Remove the grinding shaft for correction or replacement.
4. Check the four adjusting bolts on the grinding head frame.
No, tighten it. Check whether the rear wind vane of the motor is damaged.
3. The grinding head is too tight when adjusting up and down.
1. Adjust the bending deformation of the lead screw up and down
2. Two guide columns are rusted.
3. Wear of upper thread
1. Remove and correct replacement parts.
2. After cleaning with diesel oil, polish it with sandpaper.
Add clean butter after grinding.
4. The main motor is running, and the transmission part does not turn.
1. The upshift gearbox is damaged.
2. The connecting sprocket between the reduction boxes is worn.
3. The key in the sprocket is worn.
1. Check the gearbox to see if it is out of gear.
2. Check the output end of the gearbox to see if the spline is worn.
3. Check the sprocket chain. If it is worn, please replace it.
5. The reducer is heated and the oil seal is cracked.
1. There is too much oil in the gearbox.
2. The corresponding horizontal mask is pressed too tightly.
3. Both sides are not flat
1. Open the oil hole and drain some oil.
2. Check the hunger depression of the horizontal mask.
Both sliders must be flat.
6. The fixture of the cutting table is not clamped or loosened, and the cylinder of the material rack does not move.
When the jig is dragged into the carbon cutting cylinder, the action is invalid and the air pressure is unstable.
1. Clean the fixture tray with diesel oil.
2. Check the air path of the air compressor, whether the air pressure is normal, whether the gas meter pressure meets the requirements (0.6), and the pressure is not enough. Pull up the black nut above the gas meter and turn left, adjust the pressure, add special oil for cylinder, and drain water regularly.
3. Check whether the gas path is installed incorrectly.
4. Check whether the coil above the solenoid valve is burnt out.
5. Check whether the travel switch works.
6. Check the two copper bolts on the regulating cylinder body of the corresponding cylinder.
Nine: Warranty Service Terms
I. Warranty Period Commitment:
product
Warranty period (from the date of purchase of the machine)
National Three Guarantees Policy
BL after-sales service regulations
Stainless steel pipe making machine
1 year free warranty
1 year free warranty
Special instructions:
① The above service commitments are only applicable to the pipe-making machine series produced on June 5, 2008 +2008 10;
(2) Warranty certificate: the warranty shall be carried out according to the product purchase invoice or the instruction of the random warranty card. If there is no purchase invoice or warranty card or instruction manual, our company will calculate the warranty period according to the delivery date of the product.
II. Warranty Service Terms:
1. Service implementation benchmark:
It complies with the Provisions on the Responsibility for Repairing, Replacing and Returning Mechanical Goods approved by the General Administration of Quality Supervision, Inspection and Quarantine on March 27th, 2002 and the meeting of the Ministry of Information Industry on June 27th, 2002.
2. National military service:
Guanbai machinery nationwide warranty. No matter where you buy Guanbai machinery in People's Republic of China (PRC) and China (excluding Hong Kong, Macao and Taiwan), the nearest agency can provide services when there are problems that need to be replaced or repaired.
3. Warranty certificate:
According to the national three-guarantee policy, during the warranty period, the customer should submit a complete original warranty card for any failure caused by product quality.
Or purchase invoices, you can enjoy the free warranty service promised by BL products. Without the above credentials, you can only enjoy exemption from inspection according to the production date of the product.
Warranty service fee. Please keep the invoice or warranty card instructions for purchasing Guanbai machinery properly. If it is lost, please do not replace it!
4. Provisions on paid services:
Refer to the national three guarantees regulations: under any of the following circumstances, three guarantees are not implemented, but charged maintenance can be implemented:
4. 1 exceeds the validity period of three guarantees.
4.2 Failure to use, maintain or keep the product according to the requirements of the product instruction manual, resulting in damage.
4.3 Do not bear the damage caused by the disassembly of the Three Guarantees Repairer.
4.4 There is no valid three-guarantee certificate or valid invoice (the valid three-guarantee certificate is a random warranty card or purchase invoice).
4.5 Alter the Three Guarantees Certificate without authorization.
4.6 The product model or serial number on the three-guarantee certificate is inconsistent with the real thing.
4.7 No factory name, address, production date or product certificate.
4.8 Damage caused by force majeure.
The above is for reference only, and the specific provisions are subject to the current regulations of BL Company.
III. On-site service regulations:
BL can provide on-site services to consumers in a limited range of local cities, which can be divided into paid on-site services and free on-site services.
1. Provisions on free on-site service (domestic only):
Lin Bao's new pipe making machines, polishing machines, molds and other products are delivered to your door free of charge in China. No charge.
2. Producers shall bear the following responsibilities and obligations:
(a) stainless steel mechanical products should be equipped with Chinese product instructions; The product manual shall conform to the national standard GB 5296.438+0.
The provisions of the Instructions for Use of Consumer Goods; Operating procedures to express basic functions; The three-guarantee certificate shall meet the requirements of the three-guarantee certificate of mechanical products.
(2) A repair unit with maintenance qualification shall be established or designated to be responsible for the repair within the validity period of the Three Guarantees, and the name, address and contact telephone number of the repair unit shall be provided; If the name, address and telephone number of the repairer are revoked or changed, it shall promptly inform the consumer;
(three) according to the relevant maintenance agency contract or agreement, provide qualified and sufficient maintenance parts to meet the maintenance needs;
(four) according to the provisions of the relevant repair agency contract or agreement, provide the repair costs incurred within the validity period of the three guarantees; Maintenance expenses shall not be withheld in all aspects of product circulation, but shall be paid in full to the repairer;
(5) Providing technical support such as technical information and technical training according to relevant repair agency contracts or agreements;
(six) properly handle consumer complaints and inquiries, and provide consulting services in a timely manner.
IV. These Provisions shall be implemented as of June 65438+1October 65438+1October 2008.
Mechanical picture
2.50.60 General drawing of pipe making machine
3.40 General drawing of pipe making machine