Key Points for Installation and Commissioning

1.INSTALLATION AND KEY POINTS OF RUNNING MACHINE

It is a must to use 2 steel ropes up for lifting and transporting machine! First open the lid of operation door and the rear cover of main sliding rest, then hook steel ropes on 4 eye bolts which are located at 4 corners of the machine, however the intersection angle between ropes can not be over 60°and a strict care must be taken that the steel ropes can not touch any part of the machine including its housing.

Keep a strict watch for the level of the machine both front and rear, as well as left and right direction when installing the machine, in order to assure the stability for running machine.

The machine is equipped with air clutch brake, a compressed air accumulator must be adopted in the front of triple combination of compressed air, however one accumulator can be shared by 2 machines, or be used individually. The Performance Specifications are referred to DBF Air Consumption Table for the Inching Test of Clutch.

Diameter of distribution cable of the machine can not be smaller than the diameter of main switch cable of controlling box, and it is a must to connect motor and electrical controlling box to earth separately for avoiding electric leakage that will cause hurt or damage to the machine and people.

Before running machine, fill in lubricating oil or forming oil in advance, the oil capacity and oil viscosity are referred to the Explanation of Lubricating System.

Before starting machine, first need to check up whether connection joints of wires fall off or not? And whether machine screws are loosen or not? However must to check up once more for the condition of each part, screws and oil circuit ok or not after some time for test run.

For running machine, first start Lubricating pump, if the indicative green lamp lights, that means the lubricating pump is in good working order, then start main motor, however at this time as required air pressure must reach 5.5～6.0kg/cm², Inching movement is the first step for running machine, then step by step operation is followed for inspecting the running of the machine ok or not. If everything is OK, push single stroke button for test. Be known, if stop machine either under single stroke or normal running, the main slide rest should stay at rear part, thus it is convenient for adjustment and operation, otherwise it is necessary to adjust the location of relevant electrical component and cam angle which control stop position, be known also, this adjustment will be needed further as per different working speed when inching machine, the interval time of each inching movement is better over 2 seconds, so that the clutch will not be abnormally worn down. If the machine is equipped with variable-speed drive, try to inch machine at low speed, in order to reduce wear and tear of the clutch caused by slip when machine runs at high speed.

If going to make extruded product with deep hole, cooling oil must be adopted, otherwise it will bring a lot of wear and drag force to the die and maybe the die will be broken if without oil lubrication.

The cylinder pressure of feed desk should be adjusted to 3～5kg/cm², the principle is that the pressure is competent for delivery. In general, if the material is relatively soft and the diameter is smaller, the cylinder pressure requires lower. The adjustable volume of straightening wheel can not be excessive, otherwise it will add stress to feeding device, however the material should be kept on its shape and not being scratched, so as to avoid transfer fail and the happening of defective product.

Change product with different size, the below items must be changed accordingly:

1） Feeding wheel

2）Cut off die

3） Shears

4）Stop rod with different size

5） Front Punching tool and Punch rod for each station

6）P.K.O rod with different size

7） Main die, rear punch rod etc. for each station

8）The stop rod of cut off must be adjusted and the feeding length can not be longer, the principle is that the length can not be more than one tooth

9）Head trimming at last station and relevant cam need to be changed

10）The gripper of each station needs to be changed (As per different diameter and different length of gripper.)

Rear punch rod must be protruded about 0.2～0.5mm from the surface of bed die when it is fixed into bed die. When adjust dead point position before knock out for rear punch rod, it is necessary to exercise great caution that the rear punch rod can not be seized up. Say, the dead point position before knock out is decided by the principle that the rear punch rod can be turned easily by hand.

When change another size product, if the diameter is the same as well as previous product, but feeding length is different, it is not necessary to change feeding wheel and cut off die, however whether change other parts such as punch rod and bed die etc., it depends on the design condition of shaping. It is possible to take away stop rod first, then operate cut off action for testing, then take out and compare the cutting length in case of no stop rod available.

Testing keys for making a new product:

A）First, understand shaping process for each die from diameter of material and cut off length to the interactive relationship of the size.

B）Each die is used for shaping, the volume of material remains in the front punch die or in the bed die must be separated individually. Say, the material such as the head of the screw can not come back to the bed die in which the body of the screw remains, otherwise it will cause the head material broken, and it also will result that the body material can not go to the head part, so then the folding or overlapping will be happened.

C) On the condition that the product is shaped in stages, due to the different diameters of the die in the front and at the rear, the volume of each stage in the die of front or rear should be kept on sameness. If the volume in rear die is smaller than that of front die, the material in the die will produce very high extrusion pressure that will damage the die.

D) On the condition that the contraction of cross section is quite strong, the product must be extruded in the closed die for molding. Before running machine, the operator should understand the relational positions of front and read punch rods in the die, the rear punch rod must leave more than 1mm to the product, if touching product, it will produce excess pressure and cause the front punch rod broken all of a sudden, however possibly the flying broken pieces will cause hurt.

E)Same as well as the other products with different shapes, the front and rear punch rods also need to leave their correct positions first, then do a gradual test for letting them come back to their correct positions, thus for avoiding the happening of excess pressure for protecting the dies free from damage.

F) It is a must to give a close inspection on trial product issued from each process, check up whether the product is oblique or not? Whether the size and shape follow design requirement or not? Please be known, only perfect forming of previous process can create successful shaping of next process, this is a hard and rigid principle for extrusion molding.

G) Before running machine, very important point is to exam transfer gripper. Give attentions to place gripper in a correct position that means to catch the material from previous die and hold the material to the next die for waiting upsetting. Check up whether the position is leveled with and directed at the hole of the die; whether the gripper is abnormally injured; whether the clamping capacity is ok or out of order.

The cover must be closed when testing machine or running machine continuously, it is not allowed to open the cover and the people is not allowed to lean over the upper side of the die or look down at a short distance. If abnormal case happens during upsetting, it will do serious harm to the people.

If start machine, the operator must push safety button by one hand and push starting button by another hand. It is not allowed to jam safety button by some article, then one hand push starting button and another hand take testing product, this action is very dangerous, it will not only harm himself, but also cause other occasional danger.

2.Key Points of Installation & Adjustment for the Machine Supplement:

The place under the clutch bracket of the machine is strictly prohibited to contact the ground and to use any object supporting the machine in this place is also not permitted.

The block or the pad used for leveling the machine only can be put in between the bottom of the machine and the ground.

The ground plane for installing the machine must be in compliance with the requirement of the ground design for the work shop of mechanical industry.

Attention Points for Electric Earth Connection

When connecting power cable, the earth line fastener of electric cabinet must be connected with the protective line of power teminal, earth line adopts yellow & green two color plastic wire, its sectional area is the same as well as power cable.

3.Air Consumption Table for the Inching Test of Clutch

4.Wire Diameter Table for Allocated Power Cable

5.Oil Capacity Table for Each Version