1. Daily checkpoint preparation
1.1 Maintenance Project Introduction
a. Air piping: Check whether there is a leak in each pipeline.
b. Air valve and solenoid valve: Check whether the air valve and solenoid valve are properly controlled under proper operation.
c. Balancer cylinders: check whether the air leaks, check whether there is proper lubrication.
d. Die cushion: Check if air leaks and check for proper lubrication. Check whether the fixing screws of the die cushion are loose.
e. Pressure gauge: check whether the pressure gauge’s oscillating needle is normal.
a. Electrical control: Check the status of the controller and operation response. Replace the abnormal controller and tight loose parts. Check whether the fuse is of the proper size, check if the insulation of the wire is damaged, and replace abnormal wires.
b. Motor: Check whether the motor and bracket fixing screws are tightened.
c. Buttons and foot pedals: Check these switches carefully and replace them immediately if they are abnormal.
d. Relay: Carefully check the wear of the checkpoint and loose wire breakage of the wiring.
a. Clutch air-lubricated components: Eliminate all stagnant water, check the condition of the unit, and add the lubricant to the correct position.
b. Lubrication system: Please perform the maintenance of the lubrication system referring to the lubrication section described in the lubrication section of user manual. Check whether each lubrication line is broken or worn, check for leaks, cracks, or damages, and check whether the height of each oil level meter meets the standard. Under normal operating conditions, the oil tank is replaced once every three months and the tank is cleaned every six months (about 1500 hrs).
1.1.4 Mechanical parts
a. Working table: Make sure that no foreign objects are placed between the table and the machine. Make sure that there is no loosening of the table fixing screws and confirm that the level of the table is within the tolerance range.
b. Clutch: Check if there is air leakage; check the wear of the friction plate and so on.
c. Drive gear: Check if the gears and keys are tight and check whether the gears are properly lubricated.
d. Slider Adjustment (Electric Type): Check whether the slider adjustment motor is firmly fixed and confirm whether the automatic brake has no problem. Check whether the worm and worm wheel of the slider adjustment are properly lubricated. Check whether the die height indicator is accurate.
e. Motor drive: Check whether the motor shaft and pulley are loose. Belts and pulleys have worn and deformed cracks.
f. Cleaning: Clean the inside and outside of the press and remove any accumulated foreign matter.
1.2 Operation and maintenance notes:
1.2.1 Daily check essentials:
It is mainly carried out before and after the daily operation. The daily operation shall be subject to 10 hours. If the operation exceeds 10 hours, the machine shall be suspended and inspected again.
A．Before the main motor starts
1.Whether each part is full of oil
2.Whether the pressure meets the specified pressure
3.Pressure adjustment valve abnormal or not
4.Is there any abnormality in the operation of solenoid valves for clutches and brakes?
5.Is there pressure leak?
6.Pressure vessel (including balancer cylinder)
B．After the main motor starts
1. Flywheel rotation check
2. Full-operation inspection
|The oil in the oilpipelineof the lubrication system must be filled before the machine starts. The manual button can be used to fill in the oil by hand-pulling it at the same time. At the same time, check whether the pipe has ruptured or cut off. Please pay attention to refueling when manually refueling.
Is the clutch air pressure (4.0~6kg/cm2) enough? Should pay attention to changes in air pressure must be reconfirmed.
When the pressure is introduced or the pressure is changed, it must be confirmed whether the secondary pressure meets the requirement. Occasional failure to control the selected pressure, that is, the dust on adjusting valve seat must be disassembled and washed.
Drive the clutch by the inch operation and use the exhaust sound of the solenoid valve as the authentication action.
Check whether there is any air leakage in the piping connection (joint, etc.), clutch cylinder, balancer cylinder, etc.
Pay special attention to the starting condition, acceleration, vibration, and sound (idle for 5 seconds or longer). The V belt will vibrate when the rotation resistance increases.
Before operation, perform full operations such as inching motion, safety one-stroke, continuous operation, emergency stop, and foot pedaling to check for any abnormalities.
1.2.2 Weekly checkpoints
The operation rotation time shall be adjusted every 60 hours. In addition to the daily maintenance items of the pre-recorded items, the following maintenance shall be carried out.
|1. Air cleaner cleaning
2. Electrical equipment relations check
3.Is there any abnormality in the electrical wiring?
4. Cleaning of all parts
|The dismantling and cleaning of the metal mesh in the filter (but the factory piping system can be implemented once in two weeks if there is no serious accumulation of water). When the filter is blocked, the air pressure cannot rise.
The looseness of the terminal fittings, the adhesion of oil, dust, etc., the contact condition of the contacts, and the goodness of other insulation shall be checked and maintained.
Whether there is damage, breakage, loosening of the connection, etc., please pay attention to inspection and maintenance.
Remove oil, dust, debris, etc., and check for cracks.
1.2.3 Monthly inspection essentials:
Every 260 hours of monthly use will be subject to spot maintenance. In addition to the implementation of the daily and weekly conditioning requirements, the following maintenance must be carried out.
|1.Clutch and brake stroke measurement
2.V belt tension check for main motor
3.Balancer cylinder inner wall condition check
|Check that the clutch and brake strokes are within 0.5mm to 1.0mm.
The V belt can be checked by hand to see the degree of tension. The following arc is ideal for a radian of about 15 mm deep.
Check to see if there is any indentation or lubrication.
|4.Confirmation of top dead stop position
Inspection in the job
A.Pay attention to the oil status of each part
B.Pay attention to the change in air pressure
Cleaning, packing andinspection of all parts
|The top dead point stop position is unstable due to the following reasons:
1.Although the stop position is fixed, the position of the micro switch should be adjusted when the dead point is not satisfied.
2．Although the stop position is not fixed, but the error range is not large, please adjust the brake stroke.
3. When the stop position is not fixed and the error range is too large, adjust the cam fixing screw or the relevant connection position.
During operation, please pay attention to the oil status at any time. Use a hand-pressure pump to pull at any time. Do not shut off the oil and cause the bearing copper and the slider guide to burn. The heat is allowed to rise below +30°C at room temperature, and machine must be stopped when it is over hot. Motor heat is limited to the temperature of 60 °C.
Always pay attention to the pressure gauge during the operation, and avoid abnormal pressure to prevent the damage of the friction plate (especially when the pressure drops).
The upper air valve should be locked to discharge the contaminated water and release air cylinder pressure. At the same time, all parts should be cleaned and inspected for cracks or damage.
1.2.4 Annual check point preparation essentials:
Each year, the maintenance is carried out every 3000 hours. In addition to the items in the pre-recorded items, the following inspections and maintenance are required. Because of the different operating conditions, there must be wear and tear on all parts. This requires skilled maintenance personnel or service personnel with professional experience to assist in the implementation of thorough inspection and maintenance.
|1. Accuracy check
2.Clutch disassembly check
4.Check whether the foundation screws are loose
5. Electrical equipment inspection
|Slide guide clearance (0.03m/m~0.04m/m)
The inspection of the friction plate, the inspection of the wear condition, the measurement of the wear condition, the status of the wearer’s board, the wear of the outer and inner tooth surfaces of the housing, and the wear level of the “P” Ring, the spring, and the inner surface of the cylinder.
Whether the operating condition is good or not, whether the coil has burned or not, and whether there is any abnormality in the spring.
Please tighten the base screw.
The wear of the relay contacts, loosening of the connection, breakage, etc. Please exercise care.
1.3 Maintenance of electrical parts:
1.3.1 Daily maintenance
A Whether the press stop position is normal.
B The clearance and fastening of fixed-point stop proximity switch and the cam are normal or not.
C Rotate the cam switch to see if there is wear or looseness in the transmission mechanism of each part.
D Emergency stop button action is normal or not.
1.3.2 Monthly maintenance
The proximity switch for fixed-point stop detection and cam are normal or not
A. Is the fixing screw loose?
B. The distance between the cam and the proximity switch detection surface is appropriate or not.
C. Whether there is water, oil, dust, or other debris attached to the cam and proximity switch.
Operation button switch
A. The contact whether has oil and dust attached.
B. In the sliding part, whether there is dust and oil adhesion and whether the movement is sleek.
The electromagnetic valve
A. Whether the coil and exhaust part have foreign matter.
B. Whether the coil part is discolored
C. Check if the O-ring is broken and the movement is smooth.
1.3.3 Every six months maintenance
A Check all kinds of safety devices and the action is correct or not.
B Solenoid valve switch is normal or not.
C Inspection of important relays
D Inspection of metal socket welded parts.
E The pressure switch part is operating normally or not.
F Inspection of each terminal
1.3.4 Annual maintenance
Once a year’s total inspection, at this time check the following items and confirm whether they are normal. In order to prevent accidents, it is best to be regularly replaced.
A Important relay (use for press operation, restart prevention)
B Fixed-point proximity switch (or micro switch)
C Micro-switches with high operating frequency
D Operation button, emergency stop button (frequently used)
1.3.5 Other maintenance considerations
A. In addition to the electrical parts inspection described above, regular inspections are also required for special accessories.
B. Electric parts are most afraid of dust and oil, and the door must not be opened or removed.
C. Replaced parts should be fixed well, and after the replacement test run, if no problem, machine can start to work.
D. If use frequency of the machine is high, the above inspection interval should be shortened. In particular, the electromagnetic switch of the adjustment motor, if inching operation is often performed, and the contact is liable to be wasted. Special attention should be paid.
E. The manufacturer of each electrical component has specified their life expectancy. In practice, attention should be paid to the frequency of use and the quality of the work environment. It should be often checked and replaced to avoid accidents.
F. Rotary cam switch has been adjusted when ship the machine, please do not arbitrarily adjust.
2. Failure reasons and elimination methods
The break off after the upper and lower clamps hit together:
When the upper and lower clamps hit and the slider stops actuation, please follow below methods to make them disengage.
Method of disengagement with clutch actuation
1. The position of the crankshaft stopping at above bottom dead center or below bottom dead center must be confirmed.
2. Adjust the air pressure of the clutch to 4-6kg/cm2.
3. If below the bottom dead point, the motor can be forward turned in accordance with the original. If it is above the bottom dead point, the motor must be reversed turning.
4. Start the motor and make the pulley idle run and full speed rotation later.
5. Turn the operation switch to “inching” and then press and release the operation switch. After repeated operations several times, the slider will be raised to the top dead center position.
Method of disengagement with overload safety protection device (Limited oil pressure overload safety device):
1. Close the check valve in the piping of the overload device so that the oil pump cannot operate.
2. Pull the bolt of the overload safety device oil line in front of the slider to make the oil flow away, the pressure inside it decreases, and then fix the bolt in place.
3. Start the motor to drive pulley idling, and it will run at full speed later.
4. Turn the operation switch to the inching mode and then push and release the operation switch, if the clutch cannot drive, switch the overload switch to the reset position, and then repeatedly put the operation switch, so that the slider raises to the top dead center.
5. After the upper and lower molds are disengaged, open the check valve in the piping of the overload device, and the reset operation sequence is the same as that of the overload safety device, and the normal operation can be performed.
Hydraulic overload return:
The machine is equipped with a hydraulic overload safety device inside the slider. Please indicate the switch on the operation panel to the normal position.
When the press load occurs, the oil in the hydraulic chamber is squeezed out and the safety protection status disappears. At the same time, the slider action is automatically and emergency stopped.
In this case, please return it in the order of the following points.
1. Turn the operation switch to the “inching” position, and operate push button to make the slider rise to the top dead point.
2. When the slider rises to the top dead center position, the overload safety protection device recovers approximately one minute later and the oil pump automatically stops.
3. After the trial run is performed with the inching move, the normal operation can be performed.
Overload safety protection causes and elimination methods
|Pump cannot work||A. Pump micro switch for
B. Solenoid valve coil circuit stops
C. Wire breakage
D. Pipeline component failure, joint damage air leakage.
E. The pump itself fails
View and inspect
Manually View and inspect
Repair or replacement
|Pump cannot stop working||A. Insufficient oil
B. Mixing air into the pump
C. Overloaded circuit board forced return
D. Hydraulic motor steering error
E. Internal O-ring damage
F. Elastic damage to the spring
G. Internal leakage of pump
H. Pipe fittings leaking
|Check oil gauge
Air removal inspection
View and inspect
View and inspect
Replacement of wires
Repair or replacement
Intensify and replace
|Overload protection has no effect when machine overloaded||Proximity switch positioning error||View proximity switch position||Replacement or adjustment of pressure regulating valve|
3. Lubrication system
3.1 Lubrication instructions
a. During operation, please pay attention to the oil status at any time. If use hand pump, need to pull it at any time. Do not cut off the oil and cause the bearing copper and the slider guide to burn. Heating is allowed at room temperature +30°C and when the heater is overheated, machine shall stop working. Motor heat is limited to the temperature of 60°C.
b. Maintenance of immersion oil gear groove: Change the oil every three months and clean the oil tank once every six months (about 1500 hours).
c. Bearings for flywheels and transmission shafts are usually greased once every two months and checked every six months.
d. Balanced cylinder system adopts manual oil supply device, which should be inspected every other week and check points once every six months.
e. In order to ensure the lubrication between the adjusting screw and the ball seat, the machine must be installed before the first test. Add 100cc of special cycle oil R115 (R69) through the slide.
3.2 Oil add and change cycle
This machine uses grease and oil as lubricants.
a. Lubricant replacement in the gearbox: Change the oil in three months when the machine starts to use, and change it every six months after that.
b. Air piping oil supply: supplemented once a week.
c. Flywheel and bearing: This is a closed type. It is sealed in grease before assembly. Grease shall be added every two months and inspected once every six months.
d. Manual centralized oiling device: The oil collection tank of this system is equipped with an oil window to see how much oil is. When oil is insufficient, the oil shall be filled into the collection tank.
Lubrication and oil change methods should be referred to the previous “Lubrication Schedule”. For lubrication systems, please refer to the attached drawing.
(1)Lubrication when machine starting:
a. Lubricate with a manual pump before putting it into operation.
b. When resuming work for 24 hours, a manual pump is used to perform a lubrication operation with twice oil volume than the normal case, and then it can be put into production.
(2) Lubricant tank:
The amount of oil should be checked daily and supplemented as needed. Especially in the initial stage of installation, due to the need to meet the oil storage requirements in the machine, the amount of oil in the tank may be greatly reduced or decreased. It should be noted.
(3) Manual filling:
a. When manually fueling oil or grease, please turn off the power first
b. When applying grease to the chain, check the tightness of the chain and re-adjust the sprocket as needed.
When changing the oil, flush the inside of the tank and pipe lines thoroughly.
4. Structure and function
4.1 Machine body
The machine is designed by assistance of computer and has the most reasonable design for the strength of the body and the distribution of load stress.
4.2 Slider part: (Refer to the slider assembly structure diagram)
a. Slider panel:
Slider adopts our company’s new patented structure which makes it easy to install molds and change molds, saving time.
b. Electric adjustment device:
The use of a thin brake motor with push-button operation ensures stable positioning and precise positioning for quick adjustments.
c. Die height indicator:
Cooperate the electric adjustment device; its accuracy can reach 0.1mm.
d. Connecting rod:
The connecting rod used in this model is our newly developed split type. The new connecting rod improves the shortcomings of the traditional linkage deformation and increases the life of the die.
e. Equipped with balancing cylinder: (refer to the balancer assembly structure diagram)
The weight of the slider and the die can be balanced to make the press run smoothly and ensure the accuracy of the product.
4.3 Transmission part: (Refer to the diagram of the transmission assembly and clutch assembly)
a. Compound clutch brake:
The use of compound gas-pressure friction clutches and brakes reduces inertial losses in the driven part and makes adjustment and inspection easier.
b. Brake friction plate
The use of super molded brakes makes the plate good wear resistance and can instantly stop the brake at any position, high security.
c. Built-in transmission
The rotating part is completely contained in the body to improve safety. The transmission gear is immersed in the fuel tank to increase the life of the machine and eliminate noise.
4.4 Rotary cam control box:
Being placed on the right side of the press, easy to adjust and safe, important component for automatic control
4.5 Air piping control box:
Located on the left side of machine body, and attached with air pressure components such as pressure adjustment switches, lubricators, air filters, and safety pressure gauges.
4.6 Electrical control box:
Located on the right side of the machine, it is equipped with a one stroke confirmation, emergency stop air pressure confirmation and various safety circuits.
4.7 Operating control panel
Located in front of the machine, it is equipped with various indicators and control buttons to provide control signals at any time.
4.8 Special accessories:
4.8.1 Optoelectronic safety devices: (see safety article)
When necessary, photoelectric safety devices can also be added to ensure operator safety.
4.8.2 Quick Die Change Device: (see device section)
Our company’s machines can be equipped with our patented quick die lifting, die changing device, reducing your die changing time, increase production efficiency.
4.8.3 Automatic feeding end: (Refer to the feeding end assembly structure diagram)
In order to facilitate the assembly of the automatic feeding device, the customer needs to have a transmission shaft for automatic operation on the left side of the machine.
4.8.4 Die cushion: (see the structure of the die cushion assembly structure)
If necessary, a die cushion device can be added for the deep drawing process to increase the energy efficiency of the press operation.
5. Press Machine
5.1 After machine acceptance, the lubricant in the gearbox is replaced three months (750 hours) after the machine in normal operation and replaced every six months (1500 hours) thereafter, and the oil sump shall be cleaned at the same time. For other parts, the refueling cycle and lubrication line configuration diagram, please refer to “lubrication system”.
For details on oil type and oil amount, refer to the list of lubricants in the Maintenance section.
5.2 V-belt replacement:
When the V-belt is damaged, it should be replaced as follows:
Move the motor to one side of the flywheel to loosen the belt and remove it. Replace all belts at the same time. If several old belts are still sufficient for use, they should also be removed and replaced as spare parts. Because when the new and old belts are used together, the elongation of the two is uneven which may reduce the durability. In addition, even if the belt nominal length is the same, the actual size may be slightly different. Therefore, we must be very careful with matching the length of the product.
If the tension of the belt is too strong, the life of the bearing will be shortened. More severe, the shaft may also be broken. Therefore, the tension must be adjusted well so that the belt has an appropriate degree of slack. At the center point of the belt span, press with hand. If the sinking value is in accordance with the following table, the belt tension can be considered as qualified. The belt should take several days to properly fit with the belt groove grinding. It can be checked several days later and the necessary tension adjustment can be made according to the situation.
When storing belts, select areas where sunlight, heat, and moisture are less, and take care to prevent grease from adhering to them.
5.3 Check of clutch brake
The inspection of the clutch brake is very simple, and the clutch brake can be detached in the order referring to the drawing, and the entire inspection can be performed. After inspection and replacement are completed, assembly can be performed in the order in which they were disassembled. The parts must be wiped clean before assembly. The assembly number should be paid attention to in order to ensure that the clutch brake can perform its superior functions. It must be dismantled once a year for regular maintenance and maintenance. The following parts should be specially noted during the inspection.
1. Friction plate
As per the degree of wear, adjust it by adjusting gaskets above mentioned. If stop rivet head of friction plate is found to have wear, it means that its use limit has been exceeded and the new part should be replaced.
2. Piston and O-ring
The O-ring is reliable in performance and can withstand long-term use. However, if the cylinder is rusted due to moisture contained in the air (it is easy to occur when machine has long-term shutdown), the O-ring will be worn out earlier.
O-ring losses can cause air to leak, so that the brake cannot be completely released, therefore the friction plate heat up and accelerate the loss.
For these reasons, the O-ring should be replaced as soon as a leak is found. During the inspection, more attention should be paid to checking the rust in the cylinder. If the situation is serious, measures such as installing an air leakage device should be taken to solve the problem. We suggest user ask for the inspection service from our company’s technical service department.
5.4 Decomposition and assembly of transmission part
The drive part should be dismantled once a year to check its wear. The decomposition procedure can be performed with reference to the drawings. After disassembling, please completely remove the dust adhering to each part. Gas or thinner should be used to clean the places where the grease adheres. Other parts such as worn parts should be surely replaced to increase machine service life. After inspection and replacement, the assembly may be conducted in the reverse order of disassembly. When assembling, special attention should be paid to the intrusion of foreign materials such as dust, and the order of assembly should be carefully observed.
To ensure the life of the machine, please avoid using the following environment.
² Where there is a lot of dust
² Places with explosive pressure
² Places with corrosive gases
5.5 Gap adjustment of slider and guide
The clearance between the slider and the guide rail must be kept moderate to make the slider move smooth and stable. Therefore, it is necessary to adjust it appropriately. When adjusting, follow the following procedures.
a. Loosen the fixing bolts between the right side of the machine and the guide rail.
b. According to gap, decide how much linings to remove or added. First push the left side guide rail to a proper position, and then fix bolt at the front.
c. Adjust the right side guide rail to the proper position, add or remove its linings, and then fix the bolts on the front and right sides.
d. When the slider is close to the machine, the clearance between the front side of the slider and the left guide rail shall be 0.03 to 0.05mm, but the total allowable gap between the front and rear contact surfaces is 0.04~ 0.08mm. Because the upper and lower ends of the guide rail usually have large space, when the gap is measured with a thick gauge, it must be more than 30 mm deep so that a correct measured value can be ensured.
Note: The thickness of measuring gauge should be through 0.03mm, but cannot pass 0.05mm.
e. After everything is fixed, it must be tested whether the gaps of each parts are appropriate, otherwise they must be adjusted again.
Slide guide lateral profile