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PurposeMain purpose of the PBL tooling is to provide hot air

that is used for making PBL tubes

To make PBL tubes some changes and additions in Body maker and Rotating table should be done.

In Body making module: switch on to PBL on Control panel; change of the mandrel; welding mechanism

In Rotating table: adding of PBL module and change of some parts

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Changes in Body making moduleWhen you change ABL to PBL you have to concentrate onto the

Control panel, the Mandrel and the Welding mechanism of the body maker

All the switches of the Control Panel should be switched ON to PBL mode

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Change the Mandrel of the body making module for PBL tubes with the corresponding PBL tube diameter.

Changes in Body making module

Extender PBL Roll Body Carrier Guide

Bending sleeves Cooler

ABL Roll

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Changes in Body making moduleWelding mechanism

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Its first position is used for PBL welding. Hot air is blown into the area of the longitudinal seam, then follows pressing and cooling by the cooling roller. In this regards the strength of the seam is achieved as well as its compression which can be regulated. The hot air funnel is placed onto a screw sliding guiding part and thus its position towards the mandrel is precisely regulated. The hot air funnel is connected with the heater via a metal pipe.

The necessary temperature is regulated by thermo regulator with display, situated on the control panel. The air flow, coming into the heater is regulated by a fine flow control valve and is reported onto a display of flow sensor. Both are on the control panel.

When the machine is in stand-by mode, through the heater flows constant air with flow rate 90-100 l/min (assure yourself that it is MORE than 90 l/min), necessary to keep the adjusted temperature and to protect the heater from damage. The cooling roller must be situated right over mandrel’s roller.

Its second position is used for welding of ABL, but it may be used for PBL foil for additional heating and cooling to improve the ovality of the body and compression of the longitudinal seam.

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AdjustmentsThere are 2 things in body that affect shoulder welding later:

- Body diameter – if diameter is too big, ring will appear next to shoulder welding. If body diameter is too small, shoulder welding will be bad.

- Body overlap length – no more than 2mm.

There are 5 things that you can change to improve shoulder welding:

- Temperature of the hot air: min: 340°C, max: 500°C

- Hot air flow rate:90 – 100 l/min – stand-by mode. Don’t reduce this value!!!

- Hot air working flow rate range is from 100 l/min to 300 l/min and it is big, because it depends on: type of the material, its thickness and the overlap

- Pressure cooler: min 1.5 bar; max 5 bar. Never set this pressure more than 5 bar!!!

- PBL heating time (main screen): min 0.1s, max 0.3s (This value affects machine speed)

- Shoulder cooling time (main screen): min: 0.1s, max 0.3s. (This value affects machine speed)

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Changes in Rotating tableAdding of PBL module1 – Frame structure 2 – electric panel 3 – welding mechanism

4 – pneumatic panel 5 - connectors

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1. Frame structure – a frame (1) from profiles and a base plate (2), wherein all parts and elements of the module are assembled. The module is fastened to the rotating table plate with the base plate

Changes in Rotating table

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Changes in Rotating table2. Electric panel – located in a box (1) with class of protection IP44, mounted on the frame. All electronic elements and electric connectors of the PBL module are located in it. From the operator’s side there’s a thermo-regulator (2), which controls the hot air temperature. On the bottom of the box there are connections (4) for el. installation, hot air and inputs for cables of driving devices and sensors.

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Changes in Rotating table

2. Electric panel – inside the box

- Terminals (5) that connect the driving devices of the PBL module with the controlling signals of the machine;

- Servo driver (6) that drives the motor of the linear axis of the welding mechanism;

- Electronic relays (7) for the hot air heating device and

- Mechanical relays (8) for control of the technological cycle of the module.

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Changes in Rotating table3. Welding mechanism

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Its main purpose is to heat the shoulder and the tube body to the required temperature to be welded and then to be pressed and cooled.

1 - nozzle 2 – concentrator 3 – cooler 4 – hot air device

5 – pipes for hot air 6 – pneumatic cylinder 7 – linear guide

8 – servo motor 9 – base plate 10 – adjustment screws

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Changes in Rotating table4. Pneumatic panel – It consists of Al plate (1) where all the pneumatic elements are assembled: flow regulator (2), valves (3); flow sensor with display (4), pressure regulator (5)

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Changes in Rotating table

5. Connectors – one pneumatic and one electric pipe connections ending with couplings, suitable for connection of the PBL module to the main machine. By means of the pneumatic connection the module is supplied both with air and cooling water.

THINGS TO BE CHANGED IN ROTATING TABLE:

- 12 mandrel ends

- The Inductor is replaced with a metal cooler which main purpose is to cool the shoulder welding and to better its outer appearance

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AdjustmentsAttention: All the adjustments must be done when the nozzle is cold (emergency STOP of the basic machine pressed, or automatic breaker QF01 in the panel of the PBL welding module switched off), as the welding mechanism is pushed manually forward, if necessary.

Make sure coaxial position of heating head’s axis to the mandrel’s axis, which is situated to a height of 160mm from the main plate of the machine.For achieving this size the distance between the upper surface of the driving mechanism’s plate and the upper of bearing construction should be 29.5mm.

This is done in the following way: 1. The mandrel opposite to the PBL module must be dismantled and on its place to be mounted device 418.674.0004(0)- Mandrel and 418.126.0109-04(1)Д- Calibrating end piece, shown below:

Mandrel

Calibrating end piece

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Adjustments2. Put close manually the heating head next to the calibrating end piece, until

the cooler prop up frontal against the calibrating end piece. By regulating the 3 screws and the 4 screws M6 set the position of the heating head, so as the cooler to be parallel to the calibrating end piece.

Regulating screws

Screws М6

3. Dismantle the mandrel with the calibrating end piece and mount a mandrel for the respective diameter of the nozzle together with tip and placed on them a welded tube (next slide fig). Draw near manually the heating head to the mandrel until the mandrel enters into the cooler. Set the position of the heating head with the help of the screws (shown above), so as when the mandrel is entering into the cooler not to moves vertically or laterally, which reports on bad coaxiality.

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Adjustments4. Repeat the performances, described in p. 1, 2 and 3, until a maximum coaxiality of the heating head to the mandrel is achieved.

5. When an appropriate mandrel that corresponds to the nozzle’s diameter together with a tip and a shoulder on it is mounted, move manually the heating head forward until the nozzle rests on the shoulder.

Measure the interval between the rest 1 and the back plate /2/ of the linear guide with the help of caliper gauge. Set in the parameters of the control program a value of the parameter PBL Servo Distance that should be 1 mm less than the measured value. N.B: The value should not be bigger than the value measured by the adjustment in a view of the fact that the nozzle could hit the shoulder and it could be damaged.

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