Operation Manual of Crimping Machine

8/14/2019 Operation Manual of Crimping Machine

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NC40-640 Crimping Machine

Operation manual


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Contents

1. Structure and work principal.

2. Specification details.

3. Electric control.

4. Operation

5. Maintenance

6. Safety

7. trouble shooting.

8. appendix.


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1. Structure and work principal.

987

constructionNEKON

Off

On

POWER

DIE-BACKING)

TIMEREGUIATOR

A UT O M AN UA L

2

4

3

5

6

1

1. ring cylinder 2. Sliding block 3. Ring spring 4. Pressing dies 5. Positioning

magnetic plate 6. Oil tank 7. Control panel 8. Pressure Meter 9. Electric box

Work Principal

The annular piston pushes the sliding block sliding in the conical sliding path on the

inner wall of the annular cylinder, they taper fit with each other so when the sliding

blocks move forward, they also push the pressing dies into the axis direction which

press on the work piece.


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2. Major specifications

rebar sizes for the couplers 12 -40

Pressing die moving distance 15MM

Hydraulic pressure 31.5Mpa

Pump capacity 90L/MinOil type 46# hydraulic oil

Oil Tank volume 480L

Cooling system Air cooling

Moter power 11kW

Power Supply 380V 50Hz

Machine weight (kg) 1800 kgs

Machine dimensions 1320x850x1500mm

3. Electric control

3.1 Control Panel:

CYLINDER

AUTO MANUAL

6

5

PRESS RELEASE

POWER

Off

On

NEKONconstruction

MOTOR

4

On Off

3

DIE-BACKING)

TIMEREGUIATOR

21 87

1. Motor On 2.Motor Off 3.Release (dies open) 4.Press (Dies close) 5. Manual

mode 6. Automatic mode 7. Die release meter 8. Main power Switch

3.2 The electric principal refers to the attached electric diagram.


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4. Operation

4.1 input oilinput 480L 46# hydraulic oil into the tank (The oil level meter should be

above 2/3)

4.2 Power switch on

Switch on main power. Press the motor on button, checkwhether the motor rotates along the direction of its arrow to make sure the motor

rotation direction is correct.

4.3 Test the buttontest each button on the control panel to see they work correctly.

4.4 install the pressing dies and the positioning device

After finish the above initial check up, ensure the machine is in manual mode,

press the release button to move the sliding blocks backword to the end of its

position (biggest opening of the sliding blocks), then stop the motor and startinstalling the pressing dies as follows:

Use 17mm spanner to loosen the 8 fixingbolts

Select the correct dies, check the dies areintact and no cracks, the handle is not loose,to make sure they are in good condition.

Put the pressing dies on the sliding blocksby the sequence from the bottom to the top,make sure the handle sit in the positioninghole on the sliding block.

Move the sliding blocks to its max.opening by manually operate therelease button and then stop the motor.


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Set up the positioning device

Install it back on the machine.

Change the positioning bar (differentlength) according to the coupler size.This positioning bar stops the rebar in thecoupler when the coupler end touchesthe positioning plate. So this is to set uphow much length the rebar goes into the

coupler.

Take out the positioning device.Release the fixing bolts of the positioningdevice on the back of the machine.

Put all the 8 pressing dies in, tighten thefixing bolts a little bit and make sure the 8dies are in good position.

Switch on the motor, operate manually to(press the press button) close the slidingblocks so the press dies close to itsminimum opening. Stop the motor andtighten the fixing bolts.


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4.5 Adjust the hydraulic pressurePress down the red knob on the pressure meter

and at the same time turn the pressure indicator (hand) to the desired position, then

release holding down the red knob so the desired pressure is set.

Insert the coupler with the rebar inside,make sure the coupler touches thepositioning plate and the rebar touches thepositioning bar, then the right pressing canbe reached.After position calibration, tighten the lock

bolt to lock the positioning device.

Switch on the motor, put in a coupler, closethe pressing die a little by manualoperation, then adjust the position of thepositioning plate by moving the wholepositioning device forward or back work tillthe right position reached. This is to set upthe length of pressing on the coupler.

Release the positioning lock bolt so thepositioning device inside can moveeasily.


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4.6 Adjust the release timer

Its not necessary to let the pressing dies (sliding blocks) always return to their very

beginning position as this would waste time if the opening is already big enough to

receive the certain size of the coupler. The release timer is to set the time for thecylinder to return so a proper time for the cylinder to return means once the opening

is big enough for the certain coupler, the pressing dies will stop open more and the

next press can start automatcically (This function works only in automatic mode).

Enter into automatic mode by pressing the

Auto button. Set up the desired release time

(the time for the cylinder to return). Please

refer to the attached table to choose the

proposed release time.

4.7 Automatic mode.

Once the manual operation (pressing press button in manual mode) reaches the

satisfactory result of coupler pressing and the release timer is properly set, the

machine can enter into Automatic mode by pressing automatic button. In

Automatic mode, after put in the coupler and rebar in place in the machine, just

press the foot pedal then the pressing and release process shall complete

automatically.

5. Lubrication and maintenance.

5.1 The machine must be placed on ground horizontally.

5.2 Important: Before each batch production, lubricating the sliding paths (the 8

sliding paths on the inner wall of the annular cylinder, just lift the sliding block a

little it can be seen) and the sliding blocks with grease. Set the pressure to theminimum, release the sliding blocks (pressing dies) to the maximum, apply the

grease on the inner wall of the cylinder, also lift the sliding block a little bit so the

grease can be put into the sliding path with a grease gun. Then close and open

the pressing dies several times without any load. After proper greasing, wipe out

all the grease outside to ensure the pressing dies are clean.

5.3 In case of leakage of the hydraulic oil, replace the hydraulic seals.

5.4 The hydraulic oil is 46#. The best temperature should be around 30~35.

5.5 Check the sliding blocks and pressing dies regularly, ensure they are in good

position and condition..

5.6 Clean the oil system, electron valve, overflow valves regularly.


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6. Safety check up.

6.1 after switch on the motor, check around the machine to ensure no leakage of the

oil before starting work.

6.2 Stop the motor before change dies.6.3 during pressing process, never inert hands into the dies.

6.4 The machine can only be maintained by professional personnel.

6.5 Dont press the machine without load, dont work long time with pressure more

than 30 Mpa (Max. 31.5Mpa)

7. Trouble shooting and solution

Problem Cause Solution

The motor rotates the wrong

direction

Change the phase of the power supply

restriction hole of the overflow valve

jammed

clean the restriction hole

overflow valve damaged repair or replace the overflow valve

No hydraulic pressure

or low pressure

pump damaged repair or replace the pump

oil level lower than the required refill the oil

pump damaged repair or replace the pumpThe noise of the pump is

too bigshaft coupler damaged repair or replace the shft coupler

problem of the power supply for theelectromagnet

check the power supply to theelectromagnet.

the reversing valve stuck or

damaged

repaire or replace the reversing valveReversing valve does

not work

no pressure of the hydraulic system adjust the overflow valve to increase

the pressure

big noise during

pressing (dies, sliding

blocks)

bad lubrication in the sliding path proper lubrication.


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Appendix 1. Recommended parameters for standard couplers:

D*

d1

LL

e

f

d1

d dDD

L* L*

D*

f

e

Thread

M

Before

PressingRecomd. Recomd. After pressing

Recomd.

PressureDie

CouplerRebar

d D L e f D* L* Mpa) (mm)

DSD10 10 12 17.5 47 28 23 14.3-14.6 52 2.3-2.6 12

DSD12 12 16 22 58 34 30 17-17.5 64 3-3.3 14

DSD14 14 18 26 68 38 34 20.5-21.5 74 4-4.5 16

DSD16 16 20 28 77 46 38 22-23 84 5.5-6 20

DSD18 18 22 31 87 50 41 24.5-25.5 95 6.5-7 20

DSD20 20 24 34 94 53 44 27-28 103 7.5-8 24

DSD22 22 27 38 101 58 48 32-33 110 8-9 24

DSD25 25 30 42 114 67 54 34-35 122 9.5-10.5 30

DSD28 28 33 46 125 70 58 39-40 132 12-12.6 36DSD30 30 36 50 138 80 65 41-42 147 13.5-14.5 36

DSD32 32 42 57 149 81 55 49.5-50.5 160 16-17 45

DSD34 34 42 57 157 89 74 49.5-50.5 169 18-19 45

DSD40 40 48 67.5 182 104 85 59-60 194 22-23 55

The above parameters are recommended according to our couplers and the normal

conditions of our machine, tests are needed for the client to determine the best

parameters for their work.


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Appendix 2.Electric diagram for 11kw hydraulic station.:

SB1

AC contactor

relay-2

AC contactor

thermal relay

button wit

lamp Red

0.4mm2

Red

motor start/stop

motor start/stop

0.5mm2

Blue

0.5mm2

Red

2

1

L1

emergency

stop

button with

lamp Green

relay-1

start

relay

SB2

3

L3

LA

LB

LC

U V W

M

~pump motor

11KW

Circuitbreaker

AC contactor

thermal relay

control

transformer

0V

4

24V

L2

electric

bridge

AC380V


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Electric diagram for 11kw hydraulic station.

diod

button

with

lamp

button

with

lamp

button

with

lamp

relay2-1

relay3relay2Time relay

release

time

eletro-magnetic valve

for die close

eletro-magnetic

valve1

diode

5

0V24V

Controler

relay of

die open

relay of

die close

24V

HL6

indicator ofdie open

HL5

indicator of

die close

HL4

indicator ofautomatic

Time

relay

electro

connection

pressure

gauge

electro

connection

pressure

gauge

Die

open

(Release)

Dieclose

(Press)

auto-

matic

button

with

lamp

manual

Y08Y07Y06Y0524+Y04

COM X12X11X10X09COMCOM

HL3

indicator of

manual

release

time

Y03Y02Y0124+0V24+

X08X07X06X05X04X03X02X01

0V

24V


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panel diagram

Die close (Press) Die open (Release)

manual automatic

Valve

for

Die

open

Valve

for

die

close

Note:COM,X3 conn

list of connecting terminal

0V7

Y4

COM X4

24VY3

COM X324V

Y2

COM X2

24V

lamps on the panel

0V65Y5Y4Y3Y224V

X6X5COM

X4X3X24321

40V

21

0V33

Y1

2

Stop

pressure gauge

X6COM

24V

Y5COM X1

24V

release time adjustment

Start

overflowvalve

buttons on the panel

Y1X1COM

0V


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Appendix 3.Hydraulic diagram:

Check Valve

4DT

2DT1DT

oil level

indicator

overflow

valve

oil tank:480L

motor

shaft coupler

air filter

M3

air cooler

pressure gauge

M

Documents

Operation Manual of Crimping Machine