20140725 - CCM WIDE RIP MACHINE - OPERATIONAL MANUAL.pdf

8/11/2019 20140725 - CCM WIDE RIP MACHINE - OPERATIONAL MANUAL.pdf

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YX38.1-152.4-914.4

ROLL FORMING MACHINE

OPERATION MANUAL

NO. :NO. :NO. :NO. : HZYHZYHZYHZY1403140314031403- ---13131313


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YX38.1-152.4-914.4 ROLL FORMING LINE

2

CONTENTS

ESSENTIALS ........................................................................ 3

1. GENERAL INTRODUCTION ...................................................................................... 3

2. TECHNICAL PARAMETER ........................................................................................ 3

3. COMPONENT PARTS IN LINE .................................................................................. 3

4. TECHNOLOGICAL P ROCESS ................................................................................... 4

5. INSTALLATION ........................................................................................................ 4

6. OPERATION ........................................................................................................... 6

7. S AFEGUARD , MAINTENANCE & S AFE-TECHNOLOGY ............................................... 6

8. THE LUBRICATION OF MECHANICAL P ARTS ............................................................ 8

ROLL FORMING M/C ...................................................... 11

1. TECHNICAL P ARAMETER ...................................................................................... 11

2. APPLICATION & P ERFORMANCE ........................................................................... 11 3. THE FRAMEWORK S TRUCTURE ............................................................................ 12

4. RAW MATERIAL AND DIMENSION .......................................................................... 12

5. INSTALLATION , REGULATION & ATTENTION ............................................................ 13

6. DRIVE S YSTEM .................................................................................................... 14

7. S AFEGUARD , MAINTENANCE & S AFE-TECHNOLOGY ............................................. 14

8. THE DISPOSE OF MALFUNCTION .......................................................................... 16

9. THE ELECTRIC S YSTEM OPERATION .................................................................... 16

10. ASSEMBLY DRAWING ........................................................................................... 16

QUICK-WEARING PART LIST AND FITTING LIST .. 17


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3

ESSENTIALS

1. G ENERAL INTRODUCTION

This forming line is one of ROLL FORMING EQUIPMENTS FOR STEEL SHEET in

mechanical industry. It is of rational design, advanced technology. It can be used in

safety and reliance. And owing to the high efficient production, it will bring good economic

benefit.

The main work process of the forming line is:

1) Take the steel sheet to the un-coiler by hand .

2) Lead the steel sheet into roll forming equipment by hand,

3) After the coil sheet is put into roll forming line, 26 stations of roll-pressed, the

steel sheet will become the correct panel.

4) After the panel comes out from Roll Former, (the Roll Former is stopped at this

time), put the panel into the hydraulic cutting device directly, the panel will be cut

by cutting device according the required length.

As a result of application for years and uninterrupted improvement, the forming

line made by our factory possesses many advantages: compact structure, convenient

operation, reliable performance, and so on.

2. T ECHNICAL PARAMETER

DESCRIPTION SPECIFICATION

Working Height 1070mm

Feeding Width 1250&1300mm

Overall Dimension 21000 3600 1860mm

Working Speed APPROX. 12m/min

Total Weight APPROX.15Ton

The tech nical parameters in the upper table is the basic ones, the component partstechnical parameters will be referred in the next chapters, such as dimension, power,working state, etc.

3. C OMPONENT PARTS IN LINE


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The complete line is composed of the machine as following. Please refer to the

Flow Diagram.

Hydraulic un-coiler(with coil car)

Roll Forming M/C

PLC Control System

Simple Rack

The component parts of Roll Former is as follows,

a) Feeding guide device

b) Pre-cut shearer

c) Roll forming device (including 26 up/down rolling stations)

d) Hydraulic cutting device

All component parts of the complete lines can work alone and they are independent

with each other.

4. T ECHNOLOGICAL P ROCESS

The Key Flow Diagram is as following,

5. INSTALLATION

1) When the machines arrive, you should ask for operation manual first. After reading it

carefully, you should inspect the external devices of the complete line: Check

whether the component parts are all in readiness according to the detailed list of

production and the manual operation, such as the laboring protective things, the

quick-wearing parts and the in common tools. Then sets a maintained record

Steel Coil Un-coiler Roll Forming M/C

Coil Car

Simple Rack

FEEDING GUIDE


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(the chains transmission between motor and driving shaft, the chains transmission

between every roller and the gear transmission of some steps between up and down

rollers). Please check if the running parts in good lubrication, and if the safe equipments

all in line, if sure, the new machines could be put to trial with weight empty. When trial the

machine, please refer to the Installation, Regulation And Attention in chapter 3 of Roll

Forming M/C, If there is not abnormal phenomenon in the process, the machine can be

given another trial with weight loading. If the machines can run successively and produce

the correct panel, then the installation is a success.

6. O PERATION

Please refer to the Flow Diagram & The Key Flow Diagram & chapter one of general

introduction.

Lead the coil tail to the feeding guide device and then continue to lead the tail to the

first station of Roll Former by hand.The staff members leave, then starts the main motor,

the coil sheet will be sent to the hydraulic cutting device after 26 stations roll forming.

After the steel sheet is settled one time by hand, it can be put into producing

automatically. The main motor can run FWD./REV, so the steel sheet can run forward or

backward, but when the steel sheet runs backward , please remember to regulate the

speed lower, such can avoid depositing . The forming speed can be regulated by the

frquency inverter.

7. S AFEGUARD , MAINTENANCE & S AFE -TECHNOLOGY

1) Before operating the machines, you should read the Operation Manual carefully to

understand the working performance and the method of operating the machines

completely. This can make the machine work in a good condition and their service

life will be lengthened.

2) Make sure the operator has been trained before operating the machine, also must


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familiar with the items of the Operation Manual.

3) When lifting or carrying the every device of roll forming line, please do that according

to the relevant explanation and refer to the lifting/carrying drawings.

4) In order to check whether the machines can work normally, you should put them to

trial before normal production. When trials the machine , please refer to the requires

in the Operation Manual. And you had better clean all the forming-rollers in the Roll

Former with engine oil before . It is prohibited to start the machine when cleaning it,

because it is too easy to roll hands into the wheel and then the danger happens.

5) In order to operate, check and maintain the machine conveniently. So you must warn

the other staff members not to operate the machine in order to avoid the normal

working is affected even danger happens.

6) There are warning signs on the machine where the component parts of the roll

forming line may cause danger, when operating the machine, please protect the

warning signs, avoid danger happens.

7) When the machine running, if the staff need to keep close to the machine to

observed the working instance, please noticed and pay attention not to keep yourself

too close to the chain wheels, the gears and the rolling wheels etc. Especially not to

stay at the place where something may fall down. If a regulation or maintenance is

needed, please stop the machine first and then regulated it by professional after

ensure all the components are in safety state according to the INSTALLATION,

MAINTENANCE AND SAFE-TECHNOLOGY in every chapter.

8) Please add oil on the bearings and chains, add lubricating oil on the guide pin of

driving gears at regular intervals.

9) When carry the parts whose weight is over 15 kg, please use the special carried

tools; when regulate the machine, please use the special tools, too (such as hook

spanner, inner-hexagon spanner, standard plug-ruler, etc.). Please dont use hand

directly or other tools, that can avoid manglling the equipment or operator. The type

and the using method of tools will be referred to in the in common tools and

laboring protective things list .10) When regulating the machine , fix or loosen the fasten parts, lead or collect the panel,


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please wear gloves in order to avoid the fingers be scratched.

11) The positions where the danger may happened are emphasized in Operation Manual,

please pay attention to.

12) Keep sanitation around the machines. The machines should not be placed into the

high humidity environment.

13) If the machine will not be used for a long time, the rollers should be oiled and

covered with plastic film. Such can avoid the rollers rust-eaten and other sundries

falling into.

14) Please read the safe-technology of the quick-wearing parts and the main parts (such

as hydraulic elements, dies, etc.) which are referred to in the every chapter of

Operation Manual carefully.

15) If the machine or the device is drived by motor, the wirings should be connected by

professional, and refer to the Electric System Operation in every chapter to keep

the wirings are connected correctly. Please pay attention to if the power voltage is

corresponding with the power voltage of motor, all these will be expatiated in the

next chapters.

16) Make sure the working place and every machine are clean, unorderly working place

and machines are easy to cause danger.

8. THE LUBRICATION OF MECHANICAL P ARTS

Lubrication is one of the most important steps of keeping the machines service life

lengthening and work in the good condition, otherwise, the machines life will be

lengthened even the safety production will be affected, too. We will introduce the

lubrication for the parts that needed to be lubricated, please refer to the relevant

lubrication method to lubricate them.

1) The lubrication of rolling bearing

The rolling bearing of this roll forming line is suitable for working under low speed

middle load, so the failure form of the rolling bearing is wear out too fast when lubrication

is not enough in low speed. We suggest adopt grease for lubricating. The grease can be


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added on the rolling bearing by hand, or when fitting put the grease into it. Please add oil

with oil gun or press-in oil cup by hand.

When adding grease, please pay attention to some notes as follows,

a) The bearing should be filled full, if more bearings are used, the spans between

them should be filled full, too. The bearings with anti-dust cover are not needed

to be lubricated because their inner parts have been filled full with grease and

their service life are long.

b) To horizontal shaft, the span between the out bearing cap should be filled at

1/2~3/4.

c) To vertical shaft, the up bearing cap should be filled at 1/2, the down bearing

cap should be filled at 3/4.

d) When the middle/low speed bearing works in the dirty surroundings, both the

bearing and the bearing cap should be filled full.

The suitable grease for the rolling bearing are L-XBAERBA1, L-XBAERBA2,

L-XBAEBA3 (generally is called Albany grease, its working temperature is 5~40 and

dry), Please choose the suitable grease according to your working condition and

economic condition (attention: Please obey MSDS useful standard when using, changing

and emitting the lubricated grease.

The roll forming line adopts safe and reliance installation to install the bearing, so it is

convenient to lubricate at regular interval, and also can avoid dust and other sundries

falling into it. As long as the temperature is not too high, the maintenance is neednt be

done usually. Because the parts are sporadic, it is not convenient to concentrate on

providing grease. We suggest add (change) the grease 500~1000h/time.

2) The lubrication of gear

The roll forming line adopts open-type gear. The transmission abrasive grain of the

open-type gear is wearing seriously, so you should use the open type gear oil which

includes anti-wear agent and anti-tarnishing agent, and so on. The oil is very dense, so

when using it, please dilute the oil by solvent to the required viscosity. The open-type

gear isnt closed tightly, and the oil is easy to fly out, so the viscosity of the lubrication oilis very high. Under the low speed middle load transmission, the open-type gear could


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adopt grease to lubricate. Generally, L-XBAEBA1~3 general grease can be used.

If adopts oil to lubricate, you need use special spray gun. The oil is easy to volatilize,

so you should do that three hours a time, but If adopts grease to lubricate, 200~300hours

a time is needed.

3) The lubrication of chain transmission

There is wearing between pin shaft and sleeve in the chain transmission, the chain

connector will lengthen, so it is main reason why the machines transmission service life

is shortening. Then well lubrication is the most effective method to keep transmission

service life of the machine long.

The chain transmission is belong to low speed middle load, so you could adopt

L-XBAEBA1~3 general grease to lubricate by hand, please do it 200~300 hours/time.

4) The lubrication of guide pillar

The guide pillar and the guide bush of the hydraulic cutting tool need to be lubricated

well, so the machine can work in safety keep good performance and work in safety. The

guide pillar and the guide bush belong to vertical guide rail, and its working trail is

straight-line motion. When it working, part of the working surface is bared, so the

lubrication of the guide pillar not only to consider the conservation and the supply of

lubricant, but also to keep the working surface is clean and not be polluted.

The vertical guide tail of hydraulic cutting tool could lubricate by mechanical oil and

guide tail oil. The guide tail oil can keep the feeding speed is well-proportioned and locate

exactly. Generally, we suggest using 40~70# guide tail oil. Because the price of the guide

tail oil is too high, it can be changed by general mechanical oil, the 30~40# general

mechanical oil is suitable to use. Please lubricate the hydraulic cutting tool usually,

generally, do that 20~30 hours a time.


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11

ROLL FORMING M/C

1. TECHNICAL P ARAMETER

DESCRIPTION SPACIFICATION

Drive Motor/

Retarder

motor

Power 11Kw 2

Rotational speed 25r/min

Overall dimension 13000 1579 1200mm

Rolling step 26 stepsWorking speed Approx. 12m/min

Weight Approx.14Ton

2. APPLICATION & P ERFORMANCE

Roll Former is kernel part of the roll forming line. After the steel sheet is straightened

in the feeding device, it will be sent straightly to the Roll Former. After 26 stations roll

forming, then be cut, the steel sheet will become correct panel.

This Roll Former is driven by gear retarder motors (11Kw 2), The drive is

transmitted by one point five inch double-row chains (a part of retarder) to the down shaft

of 11 th station and 22 th station. Then the one point five inch chain (at the left wainscot

plates on the Roll Former) transmits the drive to other stations. A pair of meshed gears

has been set on the up shafts of the first station and the last station. When the Roll

Former working, the gears drive the up shafts of the first station and the last station, and

then other stations up shafts are passive. The steel sheet is roll forming by the up/down

rollers.

The speed of Roll Former is controlled by frequency inverter, the controlling range is

0~25m/min. and it can run FWD./REV., also can be operated by manual or auto., there is

AUTO/MAN, ADUJUSTABLE SPEED button on the plc control board.

The hoist ring is set on the machine, it can be used when the Roll Former is lifted,

please refer to the INSTALLATION , MAINTENANCE & ATTENTION in 6 th step of this


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chapter.

3. THE FRAMEWORK S TRUCTURE

. The Roll Former is made up of backseat, wainscot plates and forming section.

1) The backseat is welded with 45# light H-steel and A3 steel heavy-plate. For

guaranteeing good surface level, straight level and strength, the H-steel has been in

sand blast and partial thermal treatment. A retarder motor is fixed at the back of the

backseat, its position can be adjusted and it is can be disassembled, too. And the

motor can be lifted with the Roll Former together.

2) The A3 steel heavy-plate is welded on the backseat to make up the wainscot plate,

which is firmly connected by Pull-Rods to be strong and durable. The rollers have

been installed between the wainscot plates. The aid roll forming device could be

installed when it is needed.

3) The forming section is composed of shafts, axle sleeves and forming-rollers. The

material of the shaft is 45# steel. The main shaft has been grinded, quenched and

tempering, so it has high ability of anti-bending, anti-wresting and anti-cutting, and

can increase the strength and extend the service life. The material of the rollers is

45# steel, too. Main rollers have been quenching and tempering, and have been

coated with hard chromium (its thickness is 0.05-0.08mm), which can increase the

hardness and extend the service life and also can make the surface smooth and

artistic. The surface of the axle sleeves has been coated with hard chromium to

anti-rust. At the each tail of the shafts, there are bearings and sliders, they are used

to install and fix the roller shafts, and there are chain wheel and gear wheel at the

each tail of some shafts.

4. RAW MATERIAL AND DIMENSION

The Roll Former is suitable for middle galvanized steel sheet (its strength is G300),

the size is as following,


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Size Parameter

Thickness 0.8-1.2 mm

Feeding width 1250&1300mm

Effictive width 914.4mm

5. INSTALLATION , REGULATION & ATTENTION

1) The machine has been regulated before leaving our workshop, so it is unnecessary

to regulate the roller when it arrives at you plant. The machine should be placed

according to the Lay Out drawing that we have provided. After rectifying the surface

level, put the machine to trial with weight empty for 5 10 minutes.

2) The motor is fixed on the Roll Former, if lifts the Roll Former, the motor should be

lifted with it together. And before lift it, please check if the motor is fixed tightly.

3) After whole machine is installed, check if all the parts are in line and record it, please

refer to QUICK-WEARNG LIST, FITING LIST AND COMMON TOOLS AND

LABORING PRODUCTIVE THINGS LIST.4) Please connect the electric wirings according to the manual operation by

professional, and check if the voltage of motor power is the same as working

voltage.

5) Before running, all the sundries on the machine should be taken away and all the

bolts should be checked. The forming-rollers also should be cleaned with oil-fabric.

Only guaranteeing the safety, the machine can be brought into production.

6) Before the machine working normally, put the machine to trial with weight empty,

then check FWD/REV. and adjustable speed function according to the APPLICATION

& P ERFORMANCE in 2 nd of this chapter. If abnormal phenomenon is happening,

please stop the machine and find out where the problem is. The malfunction,

analytical method and resolve method is referred in MALFUNCTION , ANALYTICAL

METHOD AND RESOLVE METHOD in 9 th of this chapter.

7) When roll-pressing the coil sheet with different thickness, the span between up &


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down-roller should be regulated reference to the following drawing

Thickness/mm 0.8 1.0 1.1 1.2

Span/mm 0.85 1.05 1.15 1.25

l

If the user needs to roll-press the panel whose range is out of the uppers, the

number can be regulated according to the parameter in the table. But it is prohibited to

roll-press the steel material whose thickness is over 1.2 mm, or the service life will

shorten.

6. DRIVE S YSTEM

The Key Drive Diagram is as following,

Please refer to APPLICATION & P ERFORMANCE in 2 nd of this chapter and the

assemble drawing of roll forming M/C

7. S AFEGUARD , MAINTENANCE & S AFE -TECHNOLOGY

1) Before operating the machine, the Operation Manual should be read carefully for

better understanding of the working performance and the method of using the

machine. And then, the machine can be in a good condition and their service life will

lengthen.

2) Make sure do using record and maintained record of the roll forming M/C, and

records the working instance of quick-wearing-parts, driving parts, also the following

tools and laboring protective things should be recorded too. Please keep the

presented quick-wearing parts, following tools and laboring poductive things well.

3) Before starting the roll forming M/C to work every time, make sure to check if all the

parts are all in line, the fixed parts locked well, the machine can be put to produce

only under it is safe.

4) At the working period, please add oil on bearings, chains and gears at regular

DRIVEMOTOR RETARDER

NO.11& NO.22 step ofDown-Shaft

Other step ofDown Shaft

GEAR CHAIN CHAIN


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intervals. Please maintain the machine at regular intervals, too. If the machine work

12 hours continuously, add the oil every half a year.

5) Be sure not to roll-press super-thick steel sheet or which hard-scar on it. Otherwise,

the forming-rollers will be spoilt. Not to roll-press the panel with high strength, too.

6) If the machine will not be used for a long time, the rollers should be oiled and

covered with plastic film. Such can avoid the rollers rust-eaten and other sundries

falling into.

7) When the running machine makes an abnormal sound, it should be stop to check.

Only after finding out the trouble and removing it, the machine may be started again.

8) When adding oil to the rollers, be sure not to start the machine for convenience, in

that case a danger may happen easilly.

9) When operate the machine, if the speed or direction is needed to regulate, do it

slowly, then the wear and impact force will be reduced. You should avoid the

machine working for a long time and in the heavy load.

10) When regulating the machine, the drive motor should be stop as not to bring into

accident. If it is necessory to check the abnormal phenomenon when the machine is

running, please reduce the speed under 2m/min, observe the machine running by

professional and the staff should keep a little distance from the machine.

11) A standard plug-ruler should be applied to regulate the span between up &

down-roller and be sure not to instead with other face-rough things (such as knife,

steel sheet, etc.).

12) In order to operate conveniently, and the gears, chain wheels and chains need to be

added oil on for lubricating at the regular inverter, we put the chains and wheels

outside of the Roll Former. So, please dont keep your body too close to them, or an

accident may happen. But there are protective mesh cover for protect the gears and

chains, and we have set safety sign on them, please pay attention to.

13) This machine runs stably and less noise, and generally speaking, the noise source is

Roll Former, often is less than 70dB, it wont affect the staffs health. If there is any

abnormal noise, please stop it and then check it.


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8. THE DISPOSE OF MALFUNCTION

9. THE ELECTRIC S YSTEM OPERATION

The maintenance and regulation of the electric system must be done by professional,

please refer to the follows,

10. ASSEMBLY DRAWING

Please refer to the assembly drawing for Roll Former, this drawing shows out the

structure and outlooks of the Roll Former, and there is indication at the dangerous part.

NO. MALFUNCTION ANALYTICAL METHOD RESOLVE METHOD

1.The Roll Former cant be

started

The motor is bad Change the motor

The power is not be put

through or not matched

Put through the effective

power

The control circuit isnt

put through

Put through the control

power

2.

The down-shafts of

several stations cant

revolve after start the Roll

Former

The chain is wear-out

directly or falling down

Change or maintain the

chain

3. The speed cant beregulated

The frequency inverter isbroken

Change the frequencyinverter

4.The Roll Former cant run

FWD./REV.

There may any

malfunction on the

control circuit.

Maintain the control

circuit

5. There are many noise

The chains are wear-out

directly

Maintain or change the

chains

The bearing is bad Change the bearing

There is malfunction onthe motor

Maintain or change themotor.


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QUICK-WEARING PART LIST AND FITTING LIST

1) Quick-wearing list

No. NAME SPECIFICATION QTY

POSITION

01 Deep channel rollerbearing 213 2 Crosshead

03 Roller chain 24A-1 1 At the out side of thewainscot plates

04 Lock washer for circularnut D=90 2 Small circular nut

05 Small circular nut M90*2 2 On the shaft of the RollFormer

2) common tool list

No. NAME SPECIFICATION QTY POSITION

01 STANDARD TOOLBOX 1


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PLC CONTROL SYSTEM FOR ROLL FORMING MACHINE - -

CONTENTS

1. ATTENTION .............................................................................................................................

2. SYSTEM FUNCTIONS AND COMPONENTS.....................................................................

3. OPERATION BOX OF THE CONTROLLING CABINET .................................................

3-1. M ANUAL OPERATION (SUIT TRAILING ) ................................................................................

3-2. AUTO OPERATION / TOUCH SCREEN OPERATION ........................................................

3-2-1. DISPLAY AND OPERATION ...............................................................................................

4. DISPOSE OF MALFUNCTION .............................................................................................


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1. ATTENTION

1) Before operate the machine, please read the manual operation carefully and avoid

the wrong operation to cause damaging the equipment or hurting someone.

2) When the machine is running, the nonprofessional doesnt keep too close to it.

3) Do supply reliable protective earthing connection. PLCs earthing, the motors

earthing and the frequency converters earthing connection require to be placed

alone.

4) The power supply of this system is: 220V/60Hz/3p. Do check the stability of voltage.

The required limit of voltage is three-phase 220V 5%, the frequency is 60Hz 3%.

The incoming power supply should use the cable that it is more than 16 mm , the

incoming supply terminal is L1, L2, L3, N, PE. The 60A over-current protection device

and over-voltage protection device must be set to the incoming supply system.

5) Do not expose the control board right under the sunshine. Do not use this control

gear in the place where the air has been polluted for the serious powder & dust or

causticity gas and so on. Please keep dry of the gear and around environment.

6) The running environment of the system is: temperature: 0~40 , humidity: 0~80%,

without condensation, altitude: max.1000m.

7) The temperature of storage and transport environment: -25 ~55.

8) Do not permit nonprofessional to regulate and modify the device in the control board,

also not modify the parameter of frequency inverter.

9) During the power off or not work, please SHUT OFF the general power switch QF1 &

control circuit power switch QF2, and draw all the handles to stop position.

10) The MAN mode is suitable for adjusting and feeding, we suggest not use for

producing. The AUTO mode is used for producing, and it permits not to make it run in

low-speed (or low frequency inverter).

11) During the maintaining process, please SHUT OFF and lock the general power

switch QF1 to ensure safe. If requires running the machine, it is necessary that let

the qualified person operate the machine.

12) When transporting the control cabinetes, it should make a measure to take

precautions against quiver and avoid damage the component.

13) If the machine is damaged or personnel are injured for ignoring the above items, the

expense should be charged by customer himself or herself.

14) If there is any change about the wiring within the control system. Excuse for not to

notify later.


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2. SYSTEM FUNCTIONS AND COMPONENTS

A. THE S YSTEM FUNCTIONS

Adjusting buttons and switches in the PLC control system in manual mode are

operated by manual.

Using TOUCH SCREEN on the operation box of control cabinet according to the

pieces/length/holes/holes length setting to produce automatically in auto mode.

It is able to set the piece number and length in producing varied batches of steel

plates.

Adopt the encoder to follow the moving length of the steel plates automatically.

When running in auto mode, (it should be ensuring the count-wheel and the coil

sheet contacting well).

The whole processes of cutting are running automatically. The display shows the

dynamic states of machines, such as the dynamic states of batch number piece

number and length, which require no human interference.

It is able to control separately the running of the oil pump, the action of cutting tool

and the main motor in the manual mode.

It is able to store the information if power fails, It stores the information of working

batch and the number of already cut steel word from the former served again, it is

able to continue to work from the former working state.

The maximum batch number is 2 0, and the maximum piece number of each batch is

999 . The distance range of hole is 0.1-200m.

B. THE S YSTEM COMPONENTS

1) PLC: The core of this control system.

2) TOUCH SCREEN operation: Display the dynamic states of machines, setting

information of produce in auto mode.

3) Limited switch: Control the upper/lower limit of the cutting tool/punching die.

4) Encoder: Record the length date of the steel sheet running.

5) Frequency Converter Control the motor to run with different frequency.

6) Others.


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3. OPERATION BOX OF THE CONTROLLING CABINET

3-1. Manual Operation (suit trailing)

Operation of Roll Former

A. Turn on the general power supply switch QF1 and the control power supply switch

QF2, the electric circuit is put through, the POWER INDICATOR light. Draw the choice

switch MAN/AUTO to MAN position.

B. Ensure cutting tool and punching A/B die are in the upper limit position. Press the

button RUNNING FORWARD, and then the main motor run forward. Press the button

RUNNING BACKWARD, then the main motor run backward. The running speed of

Roll Former is controlled by governor potentiometer

C. Press the button PUMP START to start the pump. In the condition of the main motor

stopped, draw the CUTTING UP/DOWN to DOWN position, then the cutting tool cut

down until reaching the lower limit switch, and then the cutting action stop. (Regulate

the LOWER LIMIT SWITCH to the right position if the place of cutting does not meet

the requirement). Draw the choice switch to UP position; the cutting tool reverts until

reaching the upper limit switch. (Regulate the UPPER LIMIT SWITCH to the right

position if it doesnt revert to its place.

D. In the condition of the main motor stopped, draw the PRE-CUTTING UP/DOWN to

DOWN position, then the pre-cutting tool cut down until reaching the lower limit switch,

and then the pre-cutting action stop. (Regulate the LOWER LIMIT SWITCH to the rightposition if the place of pre-cutting does not meet the requirement). Draw the choice

switch to UP position; the pre-cutting tool reverts until reaching the upper limit switch.

(Regulate the UPPER LIMIT SWITCH to the right position if it doesnt revert to its

place.

E. Attention: please regulate the up/down limit of the cutting tool to the suitable position,

such can avoid the damage happening.

3-2. Auto Operation / TOUCH SCREEN Operation

3-2-1. Display and Operation

When power is served, the screen will firstly show the producing plant of the machinery

controlling system .It is show as follows.


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Touch Manual, the detail display information is as following:

Please select AUTO/MANUAL switch to MANUAL mode:Shears: UP If pump is running, touch up, the cutter will be cut up

Down If pump is running, touch Down, the cutter will be cut down

Machine: Touch Forward, the machine will be forward runningTouch Backward the machine will be backward running.

Touch Auto, the detail display information is as following:

Current Batch: display current running batchCurrent Length: display current running lengthLength Reset: set Current Length to zero.Single: single batch running modeMultidle: multi-batch running modeClear: clear setting data (Touch button 3 s)Parameters: enter parameters screenHome: enter home screen

Total batch can set 20 batches. Touch FORE/ NEST, change screen to set more batch.

When length and piece set finish, then set counter to 0, touch NO. batch. If selectSingle mode, when current batch running finish, the machine will be stop. If select


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PLC CONTROL SYSTEM FOR ROLL FORMING MACHINE - -Multidle mode, when all choice batch running finish, the machine will be stop.

Touch Parameters, the detail display information is as following:

Hi-SPEED DISTANCE (high speed decelerate distance ) : Ensure the machine stop

precision before cutting. The machine will be running in the low speed (5HZ).

Line compensation: The deviation of increment or shortage existed because of the

influence of the inertia and the coding apparatus count wheel precision.

Lockup Compensation: The formed sheets all have an equal deviation no matter what

the set length of the sheet is long or short.

Line compensation: The deviation of increment or shortage existed because of the

influence of the inertia and the coding apparatus count wheel precision.

Cutting Time: The time between the cutting action finished and the forming machine

start to produce the next sheet.

Pre-cutter-distance : The distance is between pre-cutter to profile cutter distance.

Compensation suggestion:Set short panel to test lockup compensation. Example: set length 0.1000m, Auto mode

running, measure the panel, if length=103mm, the Lockup Compensation=100-103=-3mmIf the Lockup Compensation is correct, set long panel test Line Compensation.

Example: set length 3.0000m, Auto mode running ,measure the panel, if length =3006mm. theLine Compensation=(3000-3006)/3=-2mm/m

Touch Machine state, the detail display information is as following:


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This screen display the cutter up limited switchs and pre-cutter up limited switchs and

E-stops state. If the cutter is not at up limited position, the display CUT AT DOWN. If

that, the machine can not running forward or backward and automation mode. If the

power is phase loss or reversal or low voltage or over voltage, it will display power err.

When last piece is running to pre-cutter, the machine will be stop. The screen will

be display as following:

4. DISPOSE OF MALFUNCTION

N

O.

Malfunction Potential reason Resolve method Analytical method

1 The system

cant

berunning

1.The power is not reach

2.PLC is not in the running

position3.PLC is burn out

1.Put through the power

supply, switch on the

Breaker QF1, QF22. Dialling PLC to RUN

Please refer to the

register on the display

operation to solve themalfunction, if the


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4.The emergency button is

pressed

5. It is not choose running

mode

state

3. Replacing PLC

4. Loosen emergency

button

5. Turn the choice switch

to AUTO or MAN position

running interface is

not display, please

check if the power

supply and the PLC

are running normally.

2 The

machine

cant

be running

1.The malfunction is as the

above NO.1

2.The cutting tool isnt

reaching the up limit.


above NO.1

2. Making the cutting tool

to up reach limit.

The cutting tool is not

reach the upper limit,

and the main motor

cant run.

3 The

cutting tool

cant

be

running


above NO.1

2. Oil motor running backward

3. The main motor is running

4. The cutting tool have

reached up/down limit


above NO.1

2.Modificate connection

3.Stop the main motor

4.Regulate limit

Attention:

If the malfunction is happened, please refer to the electric drawing, and then get the

malfunction reason and solving method.


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Steps of running in automation:

Check HI SPEED DISTANCE set 250-350mmCheck the encoder touch the panel well.Check the Forward\Backward\Pump\Cutter up\Cutter down action is right in Manual.

Operate steps of Automation

1. Choose the switch Manual/Auto to Auto on control box.2. Choose the switch Auto in touch screen. The touch screen display:

3. Example: Order 1 1.000m 8picsOrder 2 1.500m 10pics

Set:1*> 8 1.0000 02*> 10 1.5000 0

4. Choose produce mode:1)Touch Single button, then touch 1*> (Only produce order 1)

Touch Length Reset, the current length will be 0Touch Pump start to start pump on the control boxTouch Forward to running machine on the control boxThen the encode will be measure the panel length. If length=1.000m, the main motor will

be stop, then the cutter down and up. When the Counter = 8, the machine will befinish.

2)Touch Multidle button, then touch 1*> and 2*> (Produce order 1 and order 2)


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Documents

20140725 - CCM WIDE RIP MACHINE - OPERATIONAL MANUAL.pdf