Hydraulic Automatic Steel Straightening and Cutting Machine (GT4-12)

Hydraulic Automatic Steel Wire Straightening and Cutting Machine (GT4-12)
I. Precautions (Instructions before Use)
1. Before using machine, please fill with gear oil and hydraulic oil.
2. Connect with power supply according to instruction of electric cabinet.
3. Before operation each time, the machine shall conduct non-load running for 1 minute. Then operate electric cabinet for feeding materials. After confirming that Steel Bar is straight, operate it normally.
4. When adjusting curve of Steel Bar, the straightening wheel does not press too tightly, or it causes too large load on motor, and straightening wheel bearing is easy to damage. It just needs to adjust the steel bar.
II. The Purposes and Characteristic of Machine
The product is mainly applied in straightening and length cutting and applicable to cold rolling Level III Steel Bar, cold rolling plain round bar, and hot rolling coiled bar round steel.
The machine is highly automatic and pulling speed is fast. It is continuous working system and is equipped with automatic counting shutdown device. After the machine straightening, the surface of linear material shall be free from scratch. The strength loss is small and straightness accuracy is good. At the same time, the machine is easy to operate, blanking process is sample, and production efficiency is high, etc.
III. Main Technical Parameters
Machine Model
GT4-12B ModelGT6-14A
GT6-14 AModelGT4-12
GT4-12 Model
Scope of Straightening DiameterФ4-Ф12mmФ6-Ф14mm
Pulling Speed of Linear Materials45m/min48-55m/min
Specific Length of Linear Material500-9000mm()
500-9000mm (extensible)500-9000mm()
500-9000mm (extensible)
Error of Cutting Length of Linear Material±0.5cm±0.5cm
Straightening Degree of Linear Materials±2mm/m±2mm/m
Power of Traction Motor7.5KW-4
7.5KW-4 Pole11KW-4
11KW-4 Pole
Power of Oil Pump Motor4KW-4
4KW-4 Pole5.5KW-4
5.5KW-4 Pole
Quality of the Whole Machine1000kg1200kg
Appearance Dimension of Host Machine2300x800x1100mm2940x800x1100mm
V. Structure Performance of the Machine
The machine mainly consists of traction straightening part, hydraulic cutting part, blanking frame, and electric control cabinet.
4.1 Straightening Part
The part consists of two Models: straightening cylinder Model (GT4-12D) and straightening frame Model (GT4-12B).
4.11 Straightening cylinder Model (GT4-12D) mainly adjusts the straightness of linear material through adjusting shift of mould in cylinder. The rotation of straightening cylinder straightens linear material.
4.12 Straightening frame Model (GT4-12B) mainly uses several sets of straightening wheels and straightening frame rotates linear materials, which completely eliminate stress and operate linear material. Use the adjustment wire of straightening wheel to adjust the straightness of linear materials, so as to straighten linear materials.
4.2 Traction Part
The part mainly consists of drive assembly, traction assembly, and reduction gear. Use electromotor as power. Through triangular belt, drive reduction gear, which drives traction assembly, traction wheel, and chain wheel. The chain wheel drives drive traction to transport materials.
4.3 Cutting Part
The part is controlled by hydraulic pump driven by motor through magnetic exchange valve and safe pressure control valve. The piston rod of oil cylinder of trolley which balances guide rail is installed with active cutting tool, which intersects with fixed circular cutting tool installed on oil cylinder base, so as to cut the linear materials. As linear materials are cut during operation, the instantaneous resistance during cutting drives movable trolley to move, forming following-cutting tool movement. After piston rod drives the cutting tool to return, the linear material eliminates resistance. At the moment, movable trolley returns to original position under the influence of spring, and is in state of cutting. The cutting part mainly consists of motor, gear pump, magnetic exchange valve, integrated module, movable trolley, oil cylinder, balance guide rail, high-pressure oil pipe, and fuel tank. During operation, limiting stopper sends out signal to the time relay in electric control cabinet to control magnetic exchange valve. After exchange, the output hydraulic oil, under the influence of safety pressure control valve, drives oil cylinder piston and cutting tool. While passing tool bore of round cutting tool, cut the linear material operating in round cutting tool. At the moment, time relay in electric cabinet cuts off power supply of magnetic exchange valve under the influence of delaying to cut off power supply (control is about 0.12 seconds), The reset spring in oil cylinder quickly drives the reset of oil cylinder position and cutting tool, so as to complete the cyclic process of cutting off single Steel Bar. When linear material drives limiting stopper, it also sends counter signal, then counter records one time. After cutting off certain amount of linear materials, the counter automatically losses power, cutting off the circuit of system and forming automatic stop. If restart the machine, press the button of zero clearing or reset to make the counter reset, or the host machine cannot restart.
4.4 Blanking frame Part (Manual Model)
When straightening linear material passes the round cutting tool on movable trolley, after it enters blanking frame, it moves to specified dimension. Through travel switch, cut the Steel Bar.
4.5 Control of Electric Device
Consists of ordinary-Model (manual scale of travel switch) and digital control Model (encoder automatically counts)
V. Machine Installation and Debugging
5.1 Before installation of the whole machine make sure to finish the following procedures:
5.11 Check whether components are complete and positions are correct.
5.12 If the machine is close to wall or other structures, reserve enough space for equipment maintenance and site maintenance during installation of machine (generally about 1m).
5.13 Reserve broad site for raw material stock and transporting finished products.
5.14 Flat concrete foundation (11000mm lengthx1500mm widthx200mm thickness) shall be provided.
5.2 Installation of Host Machine
Use M12 expansion bolt to install several foot margins of host machine on concrete base (note: level down the host machine)
Then fix blanking frame. Pay attention that the feed opening, centers of two slots in straightening traction wheel, trolley fixed round cutting tool center, and blanking frame shall be in the same straight line. The blanking frame shall be about 20mm lower than host machine.
5.3 Connect with Power Supply
Put electric cabinet on the place which is about 1.5m away from host machine and free from vibration. Respectively insert each cable plug in socket of electric cabinet. After checking, connect power line with "power supply" binding post (note: the power line shall not be less than 6mm2 copper cable of China's standard within 30m!)
VI. The Working Principle and Adjustment Method of Hydraulic Station
The power of hydraulic station is provided by electric engine, which drives CB-FC32# gear pump to supply oil. The output hydraulic oil enters shunt integrated block and magnetic exchange valve. When it does work, oil circuit does not form pressure. Oil directly enters fuel tank from magnetic exchange valve installed on integrated block. During operation, under the command of electric cabinet, the electric cabinet controls oil circuit (due to the function of safety pressure control valve, oil circuit forms certain pressure.). While entering high-pressure oil pipe, the piston rod in oil cylinder pushes out (namely cutting off). Under the influence that time relay in control cabinet cuts off power supply (control is about 0.12 second) of magnetic exchange valve, the reset spring in oil cylinder quickly pushes piston rod of oil cylinder to reset (namely reset of cutting tool). Time relay in electric cabinet is used to adjust cutting time, generally 0.12 second (digital display is 12). In case the linear material is not cut off, add one number for cutting time.The factory setting has already been set. If not necessary, layman shall not change it, so as to protect parts.
VII. No-load Commissioning
1. Ordinary Model No-load Commissioning
Connect with power supply and turn on the power switch in electric cabinet. At the moment, the indicator light on panel is ON. Check voltmeter. If voltage is 380±10V, it is normal. If it is normal, press" go forward" button, then the motor starts. Check the rotation direction of motor (if electric machine rotates reversely, please change wire end). After it is correct, press "cut off" button to check whether cutting
2. CNC Model No-load Commissioning
Connect with power supply and turn on power switch of electric cabinet. Check voltage. If voltage is 380±10V, it is normal. After it is normal, turn on power switch of operation panel of control box. At the same time, check each parameter according to the notice on operation panel of electric equipment control cabinet. After it is normal, press "operation" button. At the moment, the motor starts. Check the rotation direction of motor. Change wire end if motor rotates reversely. After it is correct, press "cut off" button, then the cutting procedure is normal.
3. After checking, please set aside shield and press "go forward " (or "operation") button, then the machine operates for several minutes. The drive system shall be stable, without vibration or abnormal noises. The movable trolley shall be stable and flexible. If the machine is ordinary Model, install travel switch on the position of blanking frame. Check whether fastener is fixed. After all goes normal, conduct test run with load.
4. Pull linear material about 2m. Release traction wheel. Put spring bearer plate on sliding block. Install the prepared linear materials according to the procedure of feeding-hole water-proof casing-impelling assembly traction wheel-straightening frame-traction assembly traction wheel-round cutting tool hole. Then adjust proper curve to straighten Steel Bar.
Attention: after adjusting curve, tighten lock nut. Input the quantity of bar and set the length, then start the machine.VIII. Common Failure and Debugging Method
8.1 Straightening FailureFailureReasonDebugging Method
1. Steel Bar has large bendA Curve is too small
B The traction assembly traction wheel are too tightA Properly amplify curve
B Properly loosen traction wheel2. Steel Bar has small bendCurve is too largeProperly shrink curve3. Steel Bar is brokenA Feeding of Steel Bar is blocked
B Curve is too largeA Make the steel bar pass and restart the machine
B Properly shrink the curve4. Host machine vibratesA Caused by vibration of straightening frame
B Screw is loosenedA Adjust straightening frame
B Fix bolts
8.2 Failure of Feeding MaterialsFailureReasonDebugging Method1. Fail to feed materials or feed materials slowlyA Steel bar on pay-off rack is stressed
B Traction wheel does not press materialsA Make the Steel Bar pass
B Replace traction wheel or traction wheel changes slot2. Oil leakage of gearboxA Oil seal of shaft end is damaged
B Oil leakage screw at fixed bolt is loosenedA Replace oil sea
B Add sealant to fix relevant bolts3. Gearbox has noisesA Bearing failure
B Gear damage
C The upper and lower teeth impact each otherA Check replacement
B Check replacement
C Press traction wheel with force, then the noise disappear naturally4. Traction wheel does not rotateA The keys of traction wheel fall off or are damaged
B The keys of belt wheel of reduction gear fall off or are damagedFixation or replacement
8.3 Cutting-off FailureFailureReasonDebugging Method1 Error of cutting is largeA The belt of traction engine is too loose
B Traction assembly traction wheel is not pressed tightly
C The spring tension of limiting stopper is not enough
D Straightening wheel or straightening wheel bearing is damaged
E Meter counter is damaged
F Computer parameters are not correctA Adjust or replace
B Properly press
C Replace spring
D Replace
E Replace
F Check and amend2. Fail to cut off Steel BarA The cutting time is short
B Pressure is not enoughA Properly extend cutting time
B Replace pressure spring or oil pump
3. Cutting-off procedure is in failureA Rotation of hydraulic motor
B Reversing valve does not have power supply
C Reversing valve is blocked
D Electromagnetic coil of reversing valve is damaged
E Protective tube is burned
F The contact of limiting stopper is not good
G The relay of cutting tool is damagedA Adjust phase sequence of power supply
B Check switch-on
C Clean reversing valve
D Replace electromagnetic coil
E Replace
F Check limiting stopper or socket
G Check and replace4. Cutting tool does not returnA Reversing valve is blockedA Clean or replace5. Cutting tool does not return completelyA Reset springs in oil cylinder are not enough or are broken.A Replace6. Manual cutting is normal, but impacting limiting stopper is not normalContract limiting stopper is not goodMaintenance7. The reinforcement end is bend during cuttingA The internal of round cutting tool is large
B The round cutting tool is not replaced before cutting
C The spring tension of movable trolley is too largeA Adjust according to regulations
B Replace small hole round cutting tool
C Replace spring8. Switch is cut offA The cutting-off button is damaged
B Relay of cutting-tool is damaged
C Limiting stopper is in short circuitA Maintenance or replacement
B Replace
C Check travel switch and cable
8.4
8.4 Electric Appliance Failure
Failure
Reason
Debugging Method1 The motor does not operateA Power line losses phase
B No preset length or bar quantity
C Reach present bar quantityA Check power line
B After setting length and quantity, press "/confirm/i" key
C Zero clearing of bar quantity2 The motor does not startA Voltage is low
B Power line is too thin
C Relay of thermal overload protection is cut offA Turn up voltage
B Replace it with thick power line
C Check and debug overload reasons and reset thermal overload protection (after cutting off power supply, press blue button)3 Contactor, contact point has sparkA Contact is damaged
B Voltage is not enough
C Wire end is looseA Maintenance or replacement
B Check that voltage is about 380V
C Tighten wire end4 The electric cabinet has peculiar smellA Electric element is burnout
B Power line is burnoutA Check, maintain or replace
B Investigate reasons and replace the line5 Motor generates heatA Unduly adjust curve
B The preset wheel is too tight
C The cutting time is too longA Properly adjust
B Properly adjust
C Properly decrease the time6 Motor moves abnormallyA No preset bar quantity
B Reach preset bar quantityA Preset bar quantity
B Press button of zero clearing
VIII After-sales ServiceWhen the machine cannot work normally due to quality problems, if the machine is repaired for two times, then the machine still fails to work normally, our factory is responsible for replacing the machine if the machine is sold for less than 1 month. The expense shall be borne by manufacturer (subject to effective voucher). The components and parts (non-quick-wear parts)can be replaced and repaired free of charge within 3 months. If the whole machine suffers major problems such as engine, box, and gear broken, the warranty period is 6 months. If the quick-wear parts and electric appliances of the machine listed in the following table suffer problems, it is not in the scope of warranty. (remark: effective period is subject to invoice date).
GT6-14 Model/GT4-12AModel Hydraulic Steel Bar Straightening MachineName of Quick-wear PartQuantityWear-proof Casing of Feeding Hole1Wear-proof Casing of Straightening frame2Flat Traction Wheel1Traction Wheel with Groove1Straightening Wheel8 (GT4-12 straightening machine include 6 )Cutting tool1Round hole cutting tool3Cushion of Movable Trolley1Reset Spring of Movable Trolley180*68*14 (Piston) Oil Seal1Oil Seal of guide sleeve of piston rod1Guide sleeve of piston rod1Guide sleeve of movable trolley2Reset spring of piston rod1Bearing of straightening wheel16 (GT4-12 straightening machine includes 12)Adjustment wire8(GT4-12 straightening machine includes 6 )Lock nut of adjustment wire8 (GT4-12 straightening machine includes 6)Electric appliance (encoder, travel switch, etc.)
1 setStraightening triangular belt3Traction triangular belt3