AHS 4 Rolls Hydraulic Plate Bending Machine Operation and Maintenance Manual [PDF]
AHS 4 ROLLS HYDRAULIC PLATE BENDING MACHINE OPERATION AND MAINTENANCE MANUAL AKYAPAK ULUSLARARASI DIŞ TİCARET MAKİNA SAN
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AHS 4 ROLLS HYDRAULIC PLATE BENDING MACHINE OPERATION AND MAINTENANCE MANUAL AKYAPAK ULUSLARARASI DIŞ TİCARET MAKİNA SANAYİ TİCARET A.Ş.
A: Akçalar Sanayi Bölgesi Sanayi Cad. No: 8/A 16225 Akçalar BURSA / TURKEY
T: +90 224 280 75 00 F: +90 224 280 75 01 AKYAPAK-AHS-UserManual-2019.03.11
E: [email protected] W: akyapak.com.tr
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TABLE OF CONTENTS INTRODUCTION ........................................................................................................ 5 LIFE CYCLE ................................................................................................................................................. 5
GENERAL INFORMATION ........................................................................................ 7 TECHNICAL SPECIFICATIONS ................................................................................................................... 7 TECHNICAL SPECIFICATIONS ................................................................................................................... 8 PRODUCT INTRODUCTION........................................................................................................................ 9 DESCRIPTION, USAGE AREAS AND CONDITIONS OF THE MACHINE .................................................. 10
SAFETY WARNINGS............................................................................................... 11 SAFETY FACTORS ................................................................................................................................... 11 POSSIBLE RISKS ON THE MACHINE ....................................................................................................... 12 RISK OF DAMAGE ..................................................................................................................................... 12 MACHINE FUNCTIONS ............................................................................................................................. 13 PROPER OPERATION OF THE MACHINE ................................................................................................ 13 IMPROPER OPERATION OF THE MACHINE ............................................................................................ 14 PROPER OPERATOR ............................................................................................................................... 14 PROTECTION OF OPERATOR ................................................................................................................. 15 SAFETY FACTORS IN THE MACHINE INSTALLATION ............................................................................ 15 SAFETY PRECAUTIONS ........................................................................................................................... 15 CHECK THESE SAFETY PRECAUTIONS ................................................................................................. 15 CHECKING OF MAINTENANCE POINTS .................................................................................................. 16 SAFETY FEATURES.................................................................................................................................. 16 SAFETY PRECAUTIONS CHECK LIST ..................................................................................................... 18 WARNINGS ............................................................................................................................................... 19 GENERAL INFORMATION ........................................................................................................................ 20 MANUFACTURER INFORMATION ............................................................................................................ 20
IMPORTANT SAFETY PRECAUTIONS .................................................................. 21 SAFETY ..................................................................................................................................................... 21 SAFETY INFORMATION............................................................................................................................ 21 OPERATING AREA SAFETY ..................................................................................................................... 22 MACHINE SAFETY INFORMATION........................................................................................................... 24 GENERAL PRECAUTIONS ........................................................................................................................ 25 SAFETY OF THE EMPLOYEES WORKING ON THE MACHINE ................................................................ 25 PERSONAL PROTECTION EQUIPMENT .................................................................................................. 25 WARNINGS ON OPERATION .................................................................................................................... 26 STORAGE.................................................................................................................................................. 26
TRANSPORTATION ................................................................................................ 27 CHECKS TO BE DONE IN THE DELIVERY OF THE MACHINE ................................................................. 27 SAFE TRANSPORTATION OF THE MACHINE .......................................................................................... 27 A: Akçalar Sanayi Bölgesi Sanayi Cad. No: 8/A 16225 Akçalar BURSA / TURKEY
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HORIZONTAL ADJUSTMENT .................................................................................................................... 27 APPLICATION............................................................................................................................................ 28
MAINTENANCE AND INSPECTION........................................................................ 29 PROCEDURE FOR ISOLATION OF THE MACHINE .................................................................................. 29 SAFETY DURING MAINTENANCE ............................................................................................................ 29 PREVENTION OF ACCIDENTS ................................................................................................................. 30 POINTS TO BE CONSIDERED IN DAILY OPERATION ............................................................................. 32
SECTION II INSTALLATION OF THE MACHINE .................................................. 33 GENERAL INFORMATION ON THE INSTALLATION OF THE MACHINE ............ 34 INSTALLATION INSTRUCTIONS TRANSPORTATION ............................................................................. 34 TRANSPORTATION AND PLACEMENT OF THE MACHINE ..................................................................... 34 CAUTION: .................................................................................................................................................. 34 REMOVEL OF PACKAGE .......................................................................................................................... 35 PLACEMENT PLAN OF THE MACHINE ..................................................................................................... 35 INSTALLATION INFORMATION ................................................................................................................ 37
PRE-INSPECTIONS ................................................................................................. 38 SAFETY ROPE .......................................................................................................................................... 38 ELECTRICAL CONNECTION..................................................................................................................... 39 FILLING OF OIL RESERVOIR .................................................................................................................... 40 CHECKING OF LUBRICATION .................................................................................................................. 40 INSPECTION OF ELECTRIC MOTOR ROTATION DIRECTION ................................................................ 41 FOR 380/400/415V (OTHER VOLTAGES) ................................................................................................. 41
RECOMMENDED GREASE CHART ....................................................................... 43 MACHINE OPERATION........................................................................................... 44 1. UP AND DOWN MOVEMENTS OF SIDE ROLLS ................................................................................... 44 2. UP AND DOWN MOVEMENTS OF LOWER ROLL ................................................................................. 44 BUTTONS .................................................................................................................................................. 46 USAGE AND FUNCTIONS OF THE BUTTONS .......................................................................................... 46 ADJUSTMENT OF INTERNAL PRESSURE ............................................................................................... 47 MATERIAL QUALITY ................................................................................................................................. 48 PLACING THE MATERIAL ......................................................................................................................... 48 BENDING OPERATIONS ........................................................................................................................... 49 BARREL ERROR ....................................................................................................................................... 52 BARREL ..................................................................................................................................................... 52 REVERSE BARREL ERROR...................................................................................................................... 53 CYLINDER ERROR ................................................................................................................................... 53 OVALNESS ERROR .................................................................................................................................. 54 BENDING ERROR ..................................................................................................................................... 54 WRONG AXIS ERROR............................................................................................................................... 54 A: Akçalar Sanayi Bölgesi Sanayi Cad. No: 8/A 16225 Akçalar BURSA / TURKEY
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LAYOUT OF CONICAL ANGLES ............................................................................................................... 55 YOU SHALL USE HALF OF THE CAPACITY OF THE MACHINE. .............................................................. 55 CALIBRATION ........................................................................................................................................... 55 OPERATION PROCEDURE ....................................................................................................................... 55 PREPARING THE MACHINE TO CONICAL BENDING .............................................................................. 56 PLACING THE MATERIAL ......................................................................................................................... 56 1) ADJUSTMENT OF EVENNESS OF SIDE ROLLS .................................................................................. 59 ADJUSTMENT OF EVENNESS OF LOWER ROLL .................................................................................... 61 MAINTENANCE ......................................................................................................................................... 61 PREVENTIVE MAINTENANCE .................................................................................................................. 61 REGULAR LUBRICATION AND CHECKING OF OIL LEVEL ...................................................................... 62 REGULAR CLEANING ............................................................................................................................... 62 INSPECTION OF WEARABLE PARTS....................................................................................................... 62 REPAIR ...................................................................................................................................................... 62 LUBRICATION OF THE REDUCER ........................................................................................................... 62 RETURN FILTER ....................................................................................................................................... 63
SECTION III
PART LISTS ..................................................................................... 64
BODY ......................................................................................................................................................... 65 LOWER ROLL ............................................................................................................................................ 65 UPPER ROLL ............................................................................................................................................. 68 SIDE ROLL................................................................................................................................................. 70
SECTION VI AHS MAINTENANCE AND SERVICE MANUAL ........................... 72 END OF WORKDAY MAINTENANCE ........................................................................................................ 73 NOISE EMISSION RATE............................................................................................................................ 74 GENERAL SAFETY INFORMATION .......................................................................................................... 74 RECOMMENDATIONS FOR A FAULT CONDITION .................................................................................. 77
REDUCER FAULTS AND MAINTENANCE THROUGHOUT THE MACHINE ........ 83 INTERVENTION TO REDUCERS .............................................................................................................. 83 OPERATION .............................................................................................................................................. 83 MAINTENANCE ......................................................................................................................................... 83 LUBRICATION ........................................................................................................................................... 83 WARRANTY CONDITIONS ........................................................................................................................ 83 OIL TYPES ................................................................................................................................................. 86 TROUBLESHOOTING GUIDE FOR REDUCERS....................................................................................... 87
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INTRODUCTION PLEASE READ THE OPERATION MANUAL CAREFULLY AND KEEP IT FOR FUTURE REFERENCE!
Operators who would be using the machine, shall read the information in the operation manual thoroughly besides the training they will take from AKYAPAK Makine instructor, and shall have information on the operation, settings and maintenance of the machine.
Machine shall never be operated by staff who does not have a good grasp of the information in the manual.
It is forbidden to reproduce, transfer or use this document or its contents without written permission. People acting otherwise shall be responsible for any damage that may occur.
All rights, including the registration rights of a model or design submitted for patent approval or presented for use, are reserved by AKYAPAK Makina San. Tic. Ltd. Şti.
It is possible that functions that are not described in this manual are available.
Safety equipment may be represented in improper positions on some cross-sectional views used in the manual. These views are used to provide the required visual information, and the machine shall never be operated outside the specified safety positions.
The conformity of the subjects described in this manual are checked by ourselves. However, there may be some differences and it is not possible to guarantee that all these information are exactly similar.
It is possible to make changes on the machine and the document without prior information.
Subjects included in this document are regularly reviewed and changes required are added to the next issue. Your offers intended to develop the system would be gladly accepted by us.
LIFE CYCLE Life Cycle is: 10 years. (Parts retaining period to ensure functioning of the machine)
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AKYAPAK offers technical assistance and/or help to its customers when a problem occurs on the operation and repair procedures of its machines. You may contact technical service or support department both in written and oral form as specified in the relevant section of the manual when required.
Technical Service Contact Information Service Name: AKYAPAK ULUSLARARASI DIŞ TİCARET MAKİNA SANAYİ TİCARET A.Ş. Service Address: Akçalar Sanayi Bölgesi Sanayi Cad. No:8 16225Akçalar / Bursa-TÜRKİYE Service Tel: 0090 224 280 75 00 E-mail: [email protected]
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GENERAL INFORMATION TECHNICAL SPECIFICATIONS
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TECHNICAL SPECIFICATIONS Model Serial No Average Dimensions Height Length Width Weight Dimensions of Roll ROLLS Center Roll ROLLS Rear Side Roll ROLLS Bending Speed Initial Speed Power source Pre-bending Thickness Bending Thickness
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PRODUCT INTRODUCTION All operating movements of plate bending machine are performed manually. Plate material prepared for using in various fields in the industry is placed on the machine in order to bend it in the specified way. Then, desired form is obtained by bending it as specified in the operation manual. Standard features of our machine:
Conical bending mechanism
Induction hardened rolls
Digital indicator for side rolls
Completely steel (ST-52) welded construction machine body
Separate control panel
Double speed control
Rolls mounted in bearing
Upper roll cover that opens and closes hydraulically from the control panel. Upper roll is raised automatically when the cover is opened.
Conical opening and closing via control panel.
Hydraulic motor and planetary reducer driven central rolls (upper and lower rolls)
Calibration
Registered manufacturing quality with CE, ISO 9001-2008, TSEK and TURQUM certificates.
Also, in order to facilitate the bending operation:
Infinitely adjustable rotation speed
Side and central supporters for big sheet metal diameters
Material feed table
CNC Graphical control system
NC Playback control system
Replaceable upper roll (for smaller diameters)
Oil cooling system Motors with different voltages and frequencies
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DESCRIPTION, USAGE AREAS AND CONDITIONS OF THE MACHINE
Plate bending machine is designed to bend materials as cylindrical full circles (tube), half circles, arcs and cones.
Plate bending machine bends sheets with the thickness and width as specified in its specifications.
Machine is protected with various sheet construction housings.
It is intended for bending plates within the limits specified in technical specifications as per the safety, operation and maintenance instructions given in the operation manual of the machine.
Bending operation shall be performed with utmost care.
Operator shall have adequate training for the operation and maintenance of the machine, and shall be at the proper age as per the legislation of the relevant country.
Use the protection and safety equipment specified in operation manual. Also, use the personal protective equipment and/or other protective equipment required as per the operation conditions.
Safety measures include the operation of the machine as specified above.
Use the drilling machine rationally and carefully to ensure operator safety and to increase life cycle of the machine.
Read the manual carefully after receiving the machine, and then operate it.
As the plate bending machine is manufactured with advanced technology, proper use and a good maintenance plan would increase the efficient life cycle of the machine.
Human errors and improper use may cause serious damage to the machine. This may increase the wear of parts and even cause serious safety risks for the operator.
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SAFETY WARNINGS SAFETY FACTORS Upper and lower rolls of AKYAPAK 4 roll bending machine can be rotated. Operator's hand and fingers can be caught by these rolls. Ensure that parts of your clothing or your fingers are not caught in these rolls while the machine is being operated.
Do not perform repairs while the machine is being operated.
Ensure that you have turned off the machine before lifting the rear plate.
Check the safety rope after closing the plate.
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PRESS EMERGENCY STOP BUTTON IN CASE OF AN EMERGENCY OR PRESS ON THE ROPE AROUND THE MACHINE
Press emergency stop button in case of an emergency or press on the rope around the machine.
Stop the machine before maintenance and cleaning.
Never remove the safety plates.
POSSIBLE RISKS ON THE MACHINE Precautions for risks are taken on AKYAPAK 4 roll cylinder. For example:
Electrical installation is protected with a metal cover.
Another dangerous area is where the rolls rotate. Risky conditions may occur in case of wrong and erratic operation.
Safety rope is placed around the machine against accident during operation.
RISK OF DAMAGE
Operator's fingers and hands
Operator's clothing and other belongings
Deformed operating material
Third persons in material bending
Bending materials for the machine
Anyone who will be operating, installing and maintaining the machine shall read the operation manual with an applied and active manner. Do not try to bend hard materials other than aluminium and metal sheets; you may hurt yourself or cause damage to the A: Akçalar Sanayi Bölgesi Sanayi Cad. No: 8/A 16225 Akçalar BURSA / TURKEY
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machine. It is forbidden to make any modification on the machine for safety and efficiency reasons. Operating and safety instructions specified in operation manual shall be followed and applied.
MACHINE FUNCTIONS AKYAPAK 4 roll hydraulic cylinder is designed to form the material, and its other functions are given in the table below. This machine can bend closed and semi-closed tubes and cones. Machines are manufactured in different capacities and dimensions as per the thickness of the material to be bent. Check the thickness of plate before starting to bend the material. Do not attempt to bend material with the thickness higher than specified. Cylinder diameter of AKYAPAK asymmetrical bending machine, width and thickness of the material to bend are shown below. For example AHS 3100*10/14 AHS=machine type 3100=width of the material to be bent 10=thickness of the material that may be bent up to 3 three times of cylinder diameter These values are required for material with St-37 grade. Yield point=240 N/mm2 Shrinkage point=370 N/mm2
PROPER OPERATION OF THE MACHINE All bending operations shall be performed by one person, from the front of the machine, where the control panel is. Then, material shall be placed on the machine and another employee shall help him, and other bending operations shall be performed by the operator. However, operator shall take all safety precautions and check all bending operations. A safety area shall be available around the machine and no one shall enter this area other than the operator in order to achieve maximum rate of bending operations.
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IMPROPER OPERATION OF THE MACHINE No one shall be inside the safety area during bending. Power shall be cut off during repair. No one shall get over the machine in any circumstances.
PROPER OPERATOR Persons under the age of 16 are not allowed to operate 4 roll hydraulic cylinder. Operator who will be operating the machine shall confirm that he has read the manual and received all equipment. Contact AKYAPAK in case of any doubt.
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PROTECTION OF OPERATOR Operator is not required to other precautions under normal operating conditions of the machine. During operation: Employees shall wear steel boots against the risk of dropping material and work gloves for the handling of the machine. Qualified staff shall have proper equipment for machine maintenance.
Screwdriver set
Allen set
Wrench set
Lubrication gun
Gloves
Steel boots
SAFETY FACTORS IN THE MACHINE INSTALLATION AKYAPAK machine shall be placed on a hard and level ground (check the placement plan). Machine may cause serious damage and accident if it is tipped over. Material that is not properly installed cannot be bent correctly. Moreover, wrong placement of the material may cause damage. If the machine is stored, it shall be covered with tent and protected against dust.
SAFETY PRECAUTIONS Safety precautions of 4 roll cylinder machine is given below. A check list is added to ensure that these precautions are checked by the operator.
CHECK THESE SAFETY PRECAUTIONS
Always check these factors before any shift.
Please check the safety points regularly every week.
Check these safety precautions after any maintenance operation.
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CHECKING OF MAINTENANCE POINTS
Check if the position of the machine is correct.
Check for any noise from the machine.
Check whether the machine functions correctly.
Check the machine is placed correctly.
Removed any problems or errors before operating the machine. Stop the machine immediately and contact the dealer or AKYAPAK if you observe any problem during the operation of the machine. Do not skip safety elements before operating the machine or during operation.
SAFETY FEATURES
Protective cover
Main switch and circuit switch on the power panel
Power indicator on power panel that indicates the electrical power
Temperature indicator on power panel (indicates overloading)
Emergency stop button on the control panel
Switch on the control panel
Indicator on the control panel
Other buttons on the control panel
Warning labels
Condition of power cord
Connection cables of control panel
Whether manual lubrication is performed
Safety rope
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SAFETY PRECAUTIONS CHECK LIST Take a copy of this check list and use it on every inspection and operation. Mark with X after checking each feature and function and file it against a risk of fault.
CHECK LIST MACHINE NAME AND NO
CHECKED BY DATE
-PROTECTIVE COVERS = they shall be in place and screwed -ELECTRICAL ISOLATION MAIN SWITCH = it shall be installed and checked for functioning. -POWER LIGHT = it shall be installed and checked for illumination. Check for any burned bulbs. -HEAT LIGHT= it shall be installed and illuminated in case of overheating.
-EMERGENCY STOP BUTTON = it shall be installed on the control panel and checked if it stops the main motor.
-ROCKER SWITCH BUTTON (0-1) = it shall be installed on the control panel. It shall be functioning on indicator and control circuits.
-DISPLAY= it shall be installed and it shall open when the power is on.
-OTHER PANEL FUNCTION BUTTONS = they shall be installed and checked for functioning.
-WARNING PLATE = it shall be secured and placed so that it can be seen easily.
-POWER CORD = it shall be secured on the machine safely and it shall not be broken or peeled. It shall have a safety protection against mechanical damage. A: Akçalar Sanayi Bölgesi Sanayi Cad. No: 8/A 16225 Akçalar BURSA / TURKEY
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-CONTROL PANEL CONNECTION CABLE = it shall be installed and its flexible sheath shall be checked. OPERATING
CONDITIONS
WARNINGS
Do not modify components and systems of the machine without consent of AKYAPAK.
AKYAPAK warranty shall be void if any modification is made on the machine.
Do not modify the power and safety systems of the machine to ensure operator safety.
Machine shall be installed, commissioned and delivered to the customer by AKYAPAK staff only. Otherwise, AKYAPAK does not accept any responsibility and machine shall be out of warranty cover.
Loading wrong workpieces on the machine and operation may damage the machine and cause a risk for the operator.
Do not distribute this manual to other persons, companies and agencies.
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This manual includes instructions on the installation, safety applications, operation of the machine etc.
GENERAL INFORMATION Operation manual provided by the manufacturer includes required information on the machine components. Moreover, all operations in the manual are organized by considering normal operation and periodical maintenance of the machine. Therefore, instructions shall be strictly followed for correct and optimal operation of the machine. We advise you to keep the operation manual in suitable conditions in a place that can be accessed easily. Machine shall be operated by trained and qualified staff. Each part that shall be removed from the machine and replaced shall be removed by authorized technicians. All operators of the machine shall read these information, and the machine shall be operated then.
MANUFACTURER INFORMATION Please contact us using the telephone, fax or e-mail information provided above for any help requests when you have a problem related with the machine or for your spare parts orders. It is important that you provide the following information on any correspondence on the machine with the manufacturer or dealership you have purchased the machine for minimizing the procedures required:
Machine serial no.
Machine model
Date of purchase
Dealership where the machine is purchased
Description of the fault detected
Average daily operation time
Voltage and frequency information
Technical data plates that define the machine model are riveted on the machine. Machine serial number and date of production are inscribed on the technical data plate.
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IMPORTANT SAFETY PRECAUTIONS SAFETY Machine is designed as conforming to the normal safety rules. However, machine may cause accidents with risk of personal injury or death. Moreover, unsuitable operating conditions may cause damage on the machine. Machine shall be used as per its intended use. Injuries may occur when the machine is not used as per its intended use. AKYAPAK is not responsible for such a condition. Basic safety rules shall be followed in order to ensure machine operation without faults, risks or without causing an injury. Safety operations shall be wellknown by the authorized person operating the machine. Additionally, general safety rules shall be followed.
SAFETY INFORMATION In addition to the recommendations in this operation and maintenance manual, all local accident protection and environment protection legislation shall be followed. All issues such as safety information etc. related with the machine shall strictly be considered. Machine is covered with protective parts for safety reasons in order to prevent ingress of any foreign material, hand or arm to the moving or rotating parts of the machine while it is operated. Following symbols are safety symbols that shall be read and followed with special attention.
STOP DANGER MANDATORY WARNING
User may cause damage on the equipment or injury to himself when these symbols are not read or are neglected.
Stop symbol is used to indicate conditions where system/machine shall be stopped, turned off, paused or released.
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Danger symbol provides warning against specific risks and it shall always be read. If this symbol is neglected, damage to equipment or injury to staff may occur.
Mandatory symbol indicates the obligation to perform or not to perform some operations or actions in the operation areas or the obligation to make some material available or not (For example, grounding line is mandatory, keeping flammable substances away is mandatory etc.)
Warning symbol indicates that personnel shall act with caution and attention and keep their movements in specified limits in order to prevent injuries.
Read the manual carefully before operating the machine and making maintenance on it.
OPERATING AREA SAFETY Always keep the machine and your equipment clean so that they can be operated at any time and follow the instruction on maintenance operations and replacement of accessories in order to work safely. Check the plugs and cables periodically. Have AKYAPAK or an authorized technician replace it when it is damaged. Prevent soiling of the handles and grips with oil and grease. Ensure that the operation area is neat and well-illuminated. Never put any material inside the specified limits around the machine. Remove the dust and chippings on the floor, disorder increases the risk of accidents. Machine checks and operation shall be performed by the same operator. It is very dangerous using the machine by several persons, avoid such a condition.
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Do not put your hand or body parts into operating parts when the machine is operated. These behaviours are very risky. Ensure that the machine is not being operated (at standby) while changing tools or program. Do not enter the operation area of the machine when it is operated. This is very dangerous, do not attempt it.
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MACHINE SAFETY INFORMATION All power equipment are potentially dangerous. Do not put your hands in the operation area. There are compression and bending equipment in this area. Remove all your jewellery such as rings, watches etc. when you are operating the machine. Do not wear loose or baggy clothes such as unzipped or unbuttoned jackets, scarves, torn clothes or ties etc. We recommend you to wear protective equipment such as hard hats, ear protectors, protective glasses and dust mask etc. Consult your employer on the protection rules and equipment. Do not attempt to operate the machine when a fault condition occurs. Ensure that all potential risks are removed before operating the machine. Inform AKYAPAK/maintenance personnel if a fault is observed on the machine operations. Provide adequate illumination for safe operating conditions. All safety and protection equipment’s shall be used for perfect efficiency. Warning signs on the machine and recommendation in the operation manual shall always be followed. It is strictly forbidden to operate the machine when the protective covers, safety switches and any similar safety equipment are removed. Authorized personnel shall be used for lifting and moving the machine (displacement of the machine), and maintenances on the electrical and hydraulic systems. It is strictly forbidden to modify any component or change the position of a component on the machine. It is forbidden to make any adjustment, cleaning or maintenance while the machine is being operated. Always follow “Danger” and “Warning” signs on any machine equipment! If it is operated incorrectly, conditions that may cause injury or death to the operator or damage to materials or machine may occur. Besides that, if the conditions specified under 'Warning' are not applied, this may cause significant damages in some conditions. As a result, you shall always pay attention to following.
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GENERAL PRECAUTIONS The protective precautions specified in this manual may change according to the machine and its specifications. AKYAPAK is not responsible for any damage that may occur if the standard equipment on the machine is modified without the approval of AKYAPAK or if non-standard products are used in the replacement machine components. Consult AKYAPAK if the safety equipment or warning labels on the machine are damaged or missing.
SAFETY OF THE EMPLOYEES WORKING ON THE MACHINE Personnel shall be trained on the following points before operating the machine: Basic safety and accident prevention instructions, Conformity to the safety rules and periodical inspections for conformity, Illumination of the surroundings and required areas. Personnel who would be working with the machine shall use work clothes that fits on their body. As loss of concentration and any illness would cause loss of reflexes and distraction, operator shall not operate the machine in such conditions.
PERSONAL PROTECTION EQUIPMENT Following protective equipment are recommended to be used.
Strong gloves to prevent cutting, puncturing or stinging conditions while handling the material,
Earplugs that provide protection against noise,
Glasses against chipping that may be splattered,
Protective boots during handling of materials with a certain weight and size.
WARNING
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Area of danger may change as per the size of the material that is being bent by the operator besides the operation area of the machine. In brief, do not enter operation area of the materials during the operation of the machine. This is very dangerous. Never attempt this. Ensure that there is no unnecessary tools or equipment in the operation area before starting to work with the machine as this may cause damage to the machine or the operator. Pay attention to these recommendations.
WARNINGS ON OPERATION Pay attention to the following points in order to prevent electric shocks and risky conditions. Do not press the function buttons while the machine is being operated. Follow the technical codes and local wiring regulations during the installation of electrical equipment. Do not place any other equipment that may cause noise beside the machine. If the noise interferes with the signal waves, this may cause wrong movement and risks. Prevent damage to the cable and do not apply pressure on the cable, otherwise electric shock or risks may occur. Do not touch any operating part when the machine is powered on. Do not enter the operation area. These behaviours may cause injuries. Ensure that no foreign tools, equipment or person (other than operator) is present in the operation area during the operation of this machine. Then start the operation. Following areas are dangerous during the operation of the machine. Do not put your hand or body in the application area. Death or serious injury such as breaking the arm or a leg may occur.
STORAGE Machine shall be protected against external conditions (rain, extreme heat etc.) in its operation area and shall be stored indoors. All metal equipment on the machine shall be lubricated with protective grease if the machine will not be operated for a long time. Cover the machine to protect it against factors such as dust. Do not store or operate the machine in damp conditions with poisonous gas or liquid.
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Ambient temperature shall be + 10° /+ 50° C during storage. Ambient humidity shall be 10%-80%.
TRANSPORTATION CHECKS TO BE DONE IN THE DELIVERY OF THE MACHINE On the delivery of the machine, check if the delivered goods are conforming with your order and for any damage occurred during transportation. If there is a missing or damaged part, please prepare an oral and written report, taking pictures if possible, immediately. This report shall be submitted to the transportation company within 48 hours.
SAFE TRANSPORTATION OF THE MACHINE All our machines are packed in perfect packing conditions after careful internal inspection and checks. In overseas and TIR shipping, machines are specially packed using special lubricants that protect against oxidation. A report shall be issued to the transportation company in case of any damage in the machines. Also, check if all standard and optional accessories supplied with the machine are delivered.
WARNING Protect the machine against damage during transportation!
STOP Do not store in places where rain, or water drops, poisonous gas or liquid are available.
HORIZONTAL ADJUSTMENT If the level adjustment of the machine is not performed, machine may tilt and be deformed, and this would decrease the precision of the machine, affect all products and increase the vibration of the machine. Level the machine on X, Y and Z directions with a precision spirit level.
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APPLICATION Operate the machine according to the operation manual and the instructions given below. Caution: AKYAPAK does not accept any responsibility for any accident that occur due to any action of the operator that is not specified in this manual.
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MAINTENANCE AND INSPECTION PROCEDURE FOR ISOLATION OF THE MACHINE As always, turn off this machine's power system from the main switch for maintenance, repair and similar operations. Disengage hydraulic circuit pumps. Maintenance and repair operations shall be performed by the person taking the precautions specified above. If this is a simple operation, this person can be the operator after taking the precautions specified above. Main switch and hydraulic system shall be turned off is the machine is not operated. In case of an electric shock, you shall take the injured person away from the power leak first. But, this is also a potential risk. That is, electric shock is transferred to the person touching when the body of the injured person is touched. Therefore, you shall turn off the power from the main switch, if possible, or move the body of the injured person with an insulating material (wood or PVC etc.) Take the injured person to a medical facility immediately. All operations including installation, operation, maintenance, repair etc. on power installation shall be performed by authorized and qualified electric technicians. Faults that may cause unsafe operation of the machine shall be corrected as soon as possible.
SAFETY DURING MAINTENANCE Always turn off the power and hydraulic systems before starting any maintenance or replacement operation. Lock the required parts and put warning plates where required. These precautions are always required in order to prevent accidents. Perform maintenance, observation and inspection tasks periodically. Inform the operator first before any maintenance operation. Check whether the safety systems are active after any maintenance operation. Replace the improper parts of the machine immediately. Always use the genuine spare parts of the manufacturer. AKYAPAK does not provide warranty against damages in the machine caused by parts provided by other parties. Regular maintenance of the mechanic and electrical parts is very important as it would increase the life cycle of the machine and improve the performance.
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It is strictly forbidden to perform any mechanical or maintenance operation without applying the machine isolation procedure. During the removal and installation of any part, check whether it fits its place and do not forget any foreign materials during the operation. Do not get on the machine. Use genuine parts while replacing any part. Electrical components shall conform with the values specified in wiring diagrams and shall have equivalent safety properties. Contact AKYAPAK in case of doubt. Otherwise, AKYAPAK accepts no responsibility. Safety information are provided above. Please read the safety information carefully and always bear in your mind to prevent physical damages and equipment damages. Do not remove or replace any tool. This may cause fires, malfunctions or erratic operation. Do not weld directly on the machine. This may cause malfunctions or erratic operation. Do not change the parameters and internal settings of the machine, this may cause risks or erratic operation.
PREVENTION OF ACCIDENTS
DANGER Manufacturer has designed and manufactured this machine conforming with the relevant standards with reference to DIN EN-292-1, DIN EN-292-2, DIN EN-60204-1 principles for safety design harmonized standards and 98-37 EC safety directives, EC-Directives 2006/42/EC,
EC-Low Voltage Directives 73/23/EWG EC-, Electromagnetic Directives
89/336/EC i.d.F. 93/31/EC covering international directives and methods. Employer's duty here is to warn the staff against risks, to train against possible accidents, and to provide required protective safety equipment and apparatus for the safety of the operator. Operator shall be used to his/her position before starting to work, and characteristic features of the machine shall be controlled by the operator. Machine shall only be used by staff who read the operation manual and understood its contents. Directives, recommendations and general safety rules included in this manual shall be strictly followed by the user. Accident risk will be increased when one or more machine parts A: Akçalar Sanayi Bölgesi Sanayi Cad. No: 8/A 16225 Akçalar BURSA / TURKEY
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purchased from AKYAPAK are replaced without authorization or using accessories in a different way than the recommendations provided here. AKYAPAK has no legal responsibility or obligation in such operations. Machine warranty shall be void if any condition specified are valid. Switch the power off (including main power) while installing or removing the machine or while replacing any part/tool and wait for 5 minutes, then you can make the operations; otherwise, this may cause an electric shock or malfunction. Turn the power off (including main power) before daily inspection. An electric shock may occur if you make inspection or maintenance with the power on. Operator company shall put warnings signs such as 'Do not turn on the power', 'Do not operate the machine' etc. on control panel, its surroundings etc. to prevent machine operation, maintenance and inspection by unauthorized persons. Do not remove and install electrical connections of the machine when the power is on. This may cause electric shock and accidents. If any error alarm is indicated on the program, solve this condition. Run the program again after resolving the error. Ensure that all screws are tightened, no tools are left in the vicinity of machine, and all covers of the control panel and machine are closed after completing the maintenance and inspection. Otherwise, electric shock, fire and accidents may occur. AKYAPAK shall not be responsible for damages, accidents and injuries that may occur if the user changes the machine pattern on his own.
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POINTS TO BE CONSIDERED IN OPERATION Points to be considered to prevent risks If you observe any abnormal condition on the machine, press the “Emergency Stop” button to turn off the power on the machine. Correct the abnormal condition by operating manually, then activate automatic operation when all moving parts are in place. If one person is responsible for machine operation, other persons shall not operate the machine. Do not remove and install tools and perform settings on any part before the machine stops.
POINTS TO BE CONSIDERED IN DAILY OPERATION
Machine maintenance shall be performed by staff responsible for this task.
Do not alter hydraulic pressure settings.
Ensure that moving parts working with each other are centrally lubricated and specified lubricant is always available in central lubrication reservoir.
Protect operating lubricant against dust and dirt.
WARNING
Wrong movements of electromagnetic valve are 70% caused by the mismanagement of operating lubricant.
As a result, operating lubricant shall always be clean.
Ensure that all operations on the machine are completed before starting the machine.
Check the following points individually during inspection.
Is the pressure set correctly?
Is the setting of any individual part performed correctly?
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SECTION II
INSTALLATION OF THE MACHINE
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GENERAL INFORMATION ON THE INSTALLATION OF THE MACHINE INSTALLATION INSTRUCTIONS TRANSPORTATION We recommend you to transport the machine with a water-proof cover that would prevent affecting of the machine by weather conditions. Place the heavy part of the machine (reducer) to the front side of truck bed. Thus, normal driving stability shall be provided. (Figure 1). Ensure that machine is correctly placed after loading the machine. Place supporting legs to the moving parts if required. In order to secure the machine on the ground tap it to the ground from 4 corners with a wooden part as shown in figure 2.
Figure-2 Figure-1
Şekil 2
Şekil 1
TRANSPORTATION AND PLACEMENT OF THE MACHINE Always use a high capacity crane and synthetic ropes to lift the machine. Check the lifting capacity of the ropes by comparing it with the machine weight. Bring the lower roll to the upmost level and attach to the lower and upper roll as shown in the figure with a synthetic rope to lift the machine.
CAUTION: If the lower roll does not come to the upmost level, reducer will be damaged.
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Tighten the ropes before carrying and then lift the machine evenly, because the fixed weight is on the reducer side (not on the cylinders). Do not loosen the ropes, otherwise the rope slide and machine jerks.
REMOVEL OF PACKAGE Hydraulic cylinder machine is covered water-proof foil and greased to prevent it being affected from weather conditions during transport. Use suitable tar paper for vehicles with open beds or protect from weather conditions with other types of coverings during transport. Contact the transporter or dealer immediately if you observe any transport damage during the removal of the package. Use work gloves during the removal of the package. Especially, if the packing material is composed of material with high plastic or chemical content, you should avoid contact of material with children, and adults shall remove the package with protective gloves. Cleaning of machines lubricated with protective oil is as follows:
Clean the cylinders and bright surfaces with thinner.
Clean the painted surfaces using a mixture of diesel oil and water.
PLACEMENT PLAN OF THE MACHINE Placement area of the machine shall be adjusted as per the placement information and plan. Check the position of the machine, and then fix it. Use micro balance device to place the machine correctly, check for any cracks.
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INSTALLATION INFORMATION Consider the following before installing the machine.
1. Adequate space around the machine shall be left to access any part of the machine for maintenance. 2. There shall be a distance 1.5 times more of the sheet length on the front of the machine to provide lifting of the material freely. (L*1.5) 3. Leave a space on both sides of the machine to provide easy bending of the material and leave another 1 meter of space for walking space. On the area where the machine shall be placed, leave specified distances from the side and rear walls as shown in the figure below, and install it in the safe operation area. The surface where the machine shall be placed shall be level, and have the qualities to bear the machine weight. Ensure that the legs of the machine are placed on the ground.
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PRE-INSPECTIONS SAFETY ROPE Safety rope placed around the machine is removed during transport (depending on the dimensions of the machine and the area). This shall be done after the placement of the machine. Safety rope is placed on three sides of the machine. Corner pieces are used to strengthen the rope. Place these pieces on the machine and tighten their screws. Place the rope on roll wheels and tighten it. Safety rope is placed for emergency conditions. Pressing on the rope slightly shall be enough to stop the machine. You shall pull the button up to operate the machine again. Instead of safety ropes are not used for big machines that are located in a pit, emergency stop buttons are located on top of the machine for safety purposes ( 2 emg stop buttons on the top roll between 390-510 mm and 4 emg stop buttons over 540 mm) A: Akçalar Sanayi Bölgesi Sanayi Cad. No: 8/A 16225 Akçalar BURSA / TURKEY
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ELECTRICAL CONNECTION Electrical connection shall be performed by an experienced electrician. Before making the connection, check the ratings from the label on the power box and make the electrical connection according to these ratings. Plug the power cord to the socket beside the machine. Connect the power by putting it through the hole in the power box.
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FILLING OF OIL RESERVOIR ... liters of oil with the specifications of ISO HV/46 (codes of various brands of oil are shown in this page) … shall be added for this operation. a) Open the side cover next to the reducer. b) You can add hydraulic oil from the filler opening on the reservoir. Use external filter to prevent mixing of foreign material to the oil as shown below in order to transfer the oil to the reservoir from the container. c) Check the oil level from the inspection window in reservoir. -Close the cover when you are done.
Oil Filter Pump
Oil Tank
CHECKING OF LUBRICATION AKYAPAK fills the points marked with grease and delivers the machine as such. Machine lubrication system is shown in the following pages.
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INSPECTION OF ELECTRIC MOTOR ROTATION DIRECTION Operator shall check the rotation direction after the filling of the hydraulic oil is completed. Follow the instructions below for this purpose.
FOR 380/400/415V (OTHER VOLTAGES) These machines are equipped with phase order relay. This relay is intended to prevent operation of electric motor in the reverse direction. After making the electric connection, light shall illuminate in green if the phase is correct. Replace R-S phases if the light is not illuminated.
Bring the main switch on power panel to position 1.
Bring the selector switch on control panel to position 1.
Ensure that 'Power on' is illuminated; if this light is not illuminated, check the electrical connection, emergency stop button and safety rope.
Press start button, then press stop button and check the rotating direction of the electric motor.
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Motor rotating direction is indicated on the motor. Stop the motor immediately if it is rotating in the wrong direction. (For 3 seconds) If the electrical connection is wrong, disconnect power. Try again after replacing the phases of the sockets. Machine is now ready for operation. To replace hydraulic oil:
Set the cylinder rotating speed to maximum.
That is, move cylinders up and down for 30 minutes minimum.
There is a warning light that indicates dirtiness rate on hydraulic return filter.
If the arrow indicates green zone, you can continue your operation, but if the arrow indicates red zone, you may continue your operation after replacing hydraulic return filter.
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RECOMMENDED GREASE CHART Mark
Hydraulic
Power Grease Plant
Planetry Gearboxes
Unit MOBIL
Mobil DTE 25
Kup Grease 2
Mobil Gear 629
BP
Energol HLP 46
Energrease GP2
Energol GR-XP 150
SHELL
Tellus Oil 46
Livona 2
Omala Oil 150
CASTROL
Hyspin AWS 46
Helvium 2
Alpha SP 150
TEXACO
Rando Oil HD 46
-
Meropa 150
ELF
Hydrelf DS 46
-
Reductelf SP 150
TOTAL
Equivis ZS 46
-
Carter EP 150
ESSO
NUTO H 46
-
Spartan EP 0
AGIP
OSO 46
-
Blasia 150
Q8
Haendel 46
-
Goya 150
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MACHINE OPERATION MOVEMENTS 1. UP AND DOWN MOVEMENTS OF SIDE ROLLS Up and down movements of side rolls are performed with the help of circular path of the hydraulic cylinder. Evenness of side rolls are provided mechanically by the camshaft. Perfect evenness is provided by heavy steel camshaft and the moving yoked arms of side rolls. With this feature, it is very easy that side rolls take the conical bending position and smoothed.
2. UP AND DOWN MOVEMENTS OF LOWER ROLL Up and down movements of lower rolls are performed with the help of the hydraulic cylinder and eccentric cam. Evenness of lower roll is provided by the stabilizing shaft. Perfect evenness is provided by the connection of powerful camshaft and the eccentric cam of the lower roll.
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BENDING SPEED Our standard machines have 2 bending speeds. These speeds vary gradually. 1. Normal speed 2. Low speed Low speed pulls the material during pre-bending in its axis. Low and normal speed buttons are placed on the control panel. Rabbit symbol is used for normal speed, and tortoise symbol is used for low speed. Optionally, you may change the bending speed without increasing it gradually. In this option, bending option may be set as per the experience of the user and thickness of material from 0 to maximum speed. Pumps used in this system are special and do not allow an increase in the oil temperature, but controls the oil flow according to bending speed.
BUTTONS There are several buttons used to protect the operator and the machine.
USAGE AND FUNCTIONS OF THE BUTTONS After bending operation, lower roll is slowed until it touches its switch. If the lower roll does not slow, cover shall not open. Cover shall open when the user presses the cover opening button in order to remove the material. Then the upper roll is raised and material can be removed easily. Also, system does not operate and rolls do not rotate in this position. After removing the material, upper roll starts to move when you press the cover closing button, and this is continued until the cover touches the switch. Machine is ready for another casting operation. If you cannot manage the machine by the buttons: ERROR TYPE Cover does not open ROLLS do not rotate Upper roll does not move up Upper roll does not move down Cover does not close
CAUSE Lower roll is not in the lowest position Cover is open Cover is not open Cover is not open Upper roll is not in the lowest position
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REMEDY Check the lower roll switch Check the cover closing switch Check the cover opening switch Check the cover opening switch Check the upper roll down switch. E: [email protected] W: akyapak.com.tr
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ADJUSTMENT OF INTERNAL PRESSURE There are three types of hydraulic pressure in the machine.
Pressure adjustment to rotate the upper ROLL
Pressure adjustment to provide up and down movement of side rolls
Pressure adjustment for lower rolls
Pressure adjustment of upper, lower and side rolls are fixed. Changes in the following setting are strictly forbidden. Otherwise, machine shall be heavily damaged because of this. You may observe the rotation pressure value of the upper ROLL. Lower roll pressure is adjusted by the pressure safety value near the manometer (C). D may be adjusted by manometer D. Lower roll pressure value shall be determined by testing the quality, thickness and harshness of the metal to be bent.
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BENDING This machine shall be used and maintained properly and cleaned regularly in order to achieve high efficiency. Material shall be prepared before bending; and for this:
Excess parts of the material are cut with oxygen.
Rust and snow on the material are removed. Rolls may be damaged even if they are strengthened.
Both sides of the plate are cleaned.
Check the plate one more time before starting to bend the material. Clean again if there is any problem.
Physical conditions of the plate affect the quality of the material to be bent.
MATERIAL QUALITY Various materials may not provide the same results; most important factors that affect the bending quality because of the differences in quality are as follows:
Plate quality
Flow limit
Elasticity limit
Material direction
Differences in the thickness of the material.
These factors are very important. If any of these are neglected, you cannot bend the material in the dimensions you desire, for example when you want to bend a material with high elasticity with the same machine, the resulting diameter shall be different. Similarly, there would be differences between first bending and seconding operations. Moreover, these differences are valid for the same material groups. Therefore, you shall use high quality materials.
PLACING THE MATERIAL You can start the bending operation after taking all the safety precautions described. The first step of bending operation is placing the material. In order to bend with high quality, material shall be placed (compressed) between rolls properly. The starting steps for this procedure are as follows: A: Akçalar Sanayi Bölgesi Sanayi Cad. No: 8/A 16225 Akçalar BURSA / TURKEY
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1) Place the material between rolls. 2) Place the material in parallel to the axis of rolls. Side rolls may be used for facilitating this operation. Evenness can be achieved by lifting the side rolls and leaning the material to be bent to the rolls.
BENDING OPERATIONS First step is powering the machine. Steps are as follows. 1) Bring the switch on power panel to position 1. 2) Bring the switch on control panel to position 1. 3) Ensure that the power light is illuminated. If it is not illuminated, check the safety rope and the emergency stop button. 4) Press the start button. Your machine is ready for operation. You may bend the material according to the steps that will be described below. OPERATION STAGES When you operate the machine in rapid mode, you will observe that upper and lower rolls rotate together. When you operate the machine in slow mode, lower ROLL rotates only. If you compress lower roll, lower roll and upper roll contact each other and rotate together. Pressure moves in the easiest direction as per the logic of hydraulics. Therefore, resistance shall be equal so that the rotating speed of the upper and lower rolls will be equal. When the rolls are detached, endurance control system operates according to the pumping capacity. Due to the low efficiency of hydraulic pump, only the lower rolls rotate. This would not affect the bending capacity.
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OPERATION STAGES
Following figure shows the normal cylinder operation. Experience of the operator and bending time has great effect on the finishing of the product.
Ensure that center ROLL is on the lowest position before placing the plate on the machine. Bring it to the lowest position if it is not.
Load the plate to the left side of the machine. It is possible to load it on the right side. All operations are certainly dependent of reciprocal movements of side rolls.
Raise the right ROLL. This procedure causes a dumbness in the rolls, but allows that the plate is placed smoothly. Then, place the plate between two rolls and push it, thus the plate shall be compressed between rolls. It is possible to change the compression force on the machine.
Then, lower the right ROLL and push the plate to the left. Thus, we put the edge of the plate through the nearest point to the center ROLL.
Lift the left ROLL until you achieve the desired diameter and lean the plate to the right (you may read the movement of the ROLL from the digital indicator. Thickness of plate and the type of the material used is a determining factor on the diameter you will obtain.)
Stop the movement of the plate when you see that the plate will be leaned towards the right ROLL.
Here (in the figures) you can see the results of bending time.
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Sometimes, some errors may occur in the bending process. These are divided into two: 1) Barrel error 2) Reverse barrel error In fact, machines are produced by avoiding these errors. Taper of the rolls are calculated, so they can provide a good performance even in the highest thickness. However, materials with excessive thickness or thinness may cause these errors.
BARREL ERROR This is the condition where the clearance on the center of the final form is greater. This is caused by the elasticity of the rolls placed under pressure during bending process. CAUSE 1 = the fact that plate is excessively thick for the performance of the machine REMEDY 1 = you cannot solve this problem unless you use a machine with high performance. CAUSE 2 = jamming of the plate because of the excessive pressure between rolls. REMEDY 2 = slightly reduce the compression force, this may be performed at the end of the process. As you can see clearly, the length of the first straight part shall be longer when the compression force is lower.
BARREL
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REVERSE BARREL ERROR This is the condition where the center of the final form is closed and ends are open. CAUSE 1 = the fact that plate used is very thin REMEDY 1 = there is no other solution to this problem than using a machine with lower performance. CAUSE 2 = the fact that compression pressure is very weak REMEDY 2 = slightly increase the pressure of ROLL.
CYLINDER ERROR This error occurs when one side of the tube is more closed than the other side. CAUSE 1 = the fact that rolls are not perfectly in parallel to each other. REMEDY 1 = release the plate and place it on the center. If there is no progress, slightly tilt the side rolls, thus you can minimize the error.
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OVALNESS ERROR This is the condition where the ends of the final form run into each other on one side. This means that material diameter is not fixed and excessively wide in relation to the axes. CAUSE = it may be caused by the dimensions of the plate to be bent REMEDY = lower ROLL is lowered down to the lowest position and some rotation settings are performed for the tube. Lower ROLL is kept in the lowest position during this operation. Otherwise, welding or other factors may cause serious damage to the machine.
BENDING ERROR This error is caused by the fact that the force of rolls are very high. Plate comes out of the machine and irreparably damaged. Compression pressure of the rolls are reduced using the ROLL compression pressure setting device.
WRONG AXIS ERROR This condition occurs when evenness of rolls is wrong and when plates with irregular thickness are used; alignments and evenness shall be checked in this condition. There is no solution as this is caused by the material itself.
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LAYOUT OF CONICAL ANGLES Conical bending operation is performed by the conical bending system inside the machine. Conical bending operation is the hardest operation amongst bending operations. Therefore, operators who would be performing this operation shall be very experienced.
YOU SHALL USE HALF OF THE CAPACITY OF THE MACHINE. This means that machine can bend only half of its capacity. And, this is 1000mm x3mm. In other words, if the capacity of the machine is 2000x 6mm, it can bend 1000mm x3mm. If you want to obtain shortened cones as shown in the figure below, you shall be prepared as per the angle position, length and diameter of the material; angle positions shall be prepared according to the formulae below.
√
CALIBRATION After the bending operation, diameter of the material that has been transformed to a cylinder may not be fixed. Ovalness may be observed. Correcting the diameter and making the cylinder circular as much as possible is performed by calibration.
OPERATION PROCEDURE Bent material shall be removed from the machine and welded. Welding points shall be cleaned by removing the burrs both from inside and outside. Welded cylinder is placed on the machine again.
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The narrowest diameter of the oval cylinder is brought to the lowest position of the upper roll. Both side rolls are raised until they contact cylinder so that they will be at the same position. Then, side rolls are raised a little more, and pushed with a light force to provide a pear form to the cylinder. Bring the lower roll to the lowest position. Bring the calibration switch to calibration position. Therefore, rotation of the lower roll shall be cancelled and rotating power shall be transferred to the upper shaft only. Rotate the cylinder by pressing the rotation button. You shall always rotate it in the same direction. Lower the side rolls gradually at each rotation. Desired circularity shall be achieved when the contact of the side rolls with the cylinder is lost. CAUTION Max calibration capacity is 75% of max thickness.
PREPARING THE MACHINE TO CONICAL BENDING Prepare the machine to operation with the following procedure before placing the plate on the machine: 1) Ensure that the material is compressed with the support of cone by leaning the higher part of the ROLL in the center. 2) You can bend the cone correctly by leaning the side rolls. Then, a conical form may be obtained with the maximum slant.
PLACING THE MATERIAL The mouth part of the material, which is smaller, shall always be on the control unit side and shall always be leaned on the cone support.
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OPERATION PROCESS Material you want to bend is placed between the rolls on the center so that it shall be as near as possible to the own axes of the rolls. Try to achieve the best alignment at this time. All following operations is the same as the normal bending procedure. You shall clean and prepare the plate before the start of the operation as conical bending is a difficult procedure and machine works under a specific pressure. Side supports of the machine slightly opens as the cones are pushed during conical bending. If this happens, check the dimensions of the cone again and ensure machine may perform this operation. POINTS TO BE CONSIDERED DURING CONICAL BENDING AND PLACEMENT OF CONE MATERIAL The small diameter of the material shall be leaned on the cone support roll. Bring the side of the angled cone plate that you will start to bend in parallel with the axes of lower and upper shafts. Cone is compressed by pressing the lower roll up button after bringing the lower roll cone button on the control panel to the cone position when 5 to 8 mm is left to the compression of the plate after raising the lower roll. Compression shall be visually inspected in this operation. Plate shall be rotated from the bigger diameter side of the plate that shall be bent conically for bending operation. Side shaft is slightly raised in parallel position. Then, side shaft cone button is brought to cone position. Bending operation is started when the desired cone angle is achieved by pressing the lifting button. When the shaft comes over the other side shaft, the other side shaft also brought to conical form in the same way. When the ends of the plate come together in conical bending operation, plate is spot welded from the inside and outside. After the machining of weld surfaces, calibration is performed. Lower cone is closed when this operation is completed. Lower roll is lowered. Cover is opened using the cover opening/closing button. Upper shaft is raised and operation is completed. If these operations are not followed:
You compress it further instead of adequately compressing with the lower shaft from the bigger cone side of the plate.
You may inadvertently compress the cone plate as parallel instead of the cone.
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If you try to compress the cone plate by lifting the cone when lower shaft is in the lowest position,
Machine does not bend conically (you may damage the shaft, cone thrust of the machine or the material you want to bend conically.)
If the surface that contact the cone thrust roll of the material is rolled up or down, if it is crushed or deformed, operations described above shall be performed. NOTE = Ensure that you have only compressed to provide rotation of the plate at a distance of 5 to 10 cm from the bigger diameter side of the conical plate. Material is removed from the machine as follows at the end of the bending operation.
Lowers the level of lower ROLL.
Press button no. 2, upper cover shall be opened, and then upper ROLL shall move upwards.
“
1. Bent plate is removed from the upper ROLL. 2. Upper ROLL moves upwards and cover is closed by pressing button no. 1.
Each move is checked from the limit switch to ensure that these operations are performed smoothly and safely.
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1) ADJUSTMENT OF EVENNESS OF SIDE ROLLS Ensure that conical bending device is turned off before performing the pre-operation described above. If x>y, adjustment screw (A) is rotated counter-clockwise. If x