簡述

Introduction

輥型機(jī)是輪輞的專用加工設(shè)備，通常輥型加工包括3個工序（第1序，第2序和第3序成型），每一序需要1臺輥型機(jī)，每臺輥型機(jī)包括以下部分：輥型機(jī)主機(jī)、液壓系統(tǒng)、PLC控制系統(tǒng)、上下料機(jī)構(gòu)和輥型模具。

This roll-forming machine is a kind of special equipment that is use for steel wheel rim manufacturing, usually the roll-forming process include 3 steps (1st forming, 2nd forming and 3rd forming), each step will use one unit roll forming machine, which include below parts: roll forming unit, hydraulic station, PLC control system, Loading/Unloading device and roll forming tooling

設(shè)備規(guī)格

Specification

設(shè)備型號	Model Number	GX23/300-AH
輥型力	Roll Forming Force	230KN
液壓站電機(jī)功率	Motor Power of Hydraulic Station	82.5KW
主軸安裝模具長度	Spindle Length for Installing Molds	320mm
上下主軸轉(zhuǎn)速(可調(diào))	Upper & Lower Spindle Speed range	0 ~ 320r/min
主軸材質(zhì)和直徑	Spindle Material & Diameter	40CrMo, Φ145mm
上下主軸間距	Distance between Upper & Lower Spindle	240 mm ~ 380mm
下軸軸向可調(diào)范圍	Axial Adjusting Range of Lower Spindle	±2mm
下主軸行程(裝模處軸的直徑145mm)	Stroke of Lower Spindle: (axial diameter 145mm at die-setting)	140mm
下主軸接近速度	Loading Speed of lower Spindle	185mm/s
下主軸工進(jìn)速度可調(diào)范圍	Feeding Speed’s Adjusting Range of Lower Spindle	2~10mm/s
下主軸可調(diào)傾角	Tilting Angle Adjusting Range of Lower Spindle	-0.34° to +0.17°
額定輸入電壓	Rated Input Voltage	380V/3phase
額定輸入容量	Rated Input Power	110Kw

輥型模具

Roll Forming Tool

輥型機(jī)上要安裝輥型模具，每個工序一套輥型模具。

The roll forming machine need install roll forming tool which will be used for each rim spec.

機(jī)床調(diào)整特點(diǎn)

Machine’s Adjustment  

主軸的調(diào)整 /Main Spindle’S Adjustment

每個主軸都由擺臂支撐，擺臂采用鉸接與主軸相連，擺臂的鉸接點(diǎn)采用球軸承，后端的一個安裝在偏心機(jī)構(gòu)上，通過偏心實(shí)現(xiàn)主軸的傾斜，為使兩主軸同步對稱相向調(diào)整，兩偏心機(jī)構(gòu)用機(jī)械裝置耦合在一起，通過手輪進(jìn)行調(diào)整，其作用為 ：

Every main spindle is hold by pendular arms, which connects with main spindle by hinge. The hinge point of pendular arm adopts ball bearing. The back one is installed on an off-centre device. The main spindle inclined is realized through eccentric. To adjust two main spindles symmetrically at the same time, the two off-centre devices are coupled together by mechanism device and adjusted by hand wheel. Its main function is following:

1)提供成型過程中所需的定型力，可以進(jìn)一步控制產(chǎn)品質(zhì)量。

Provide needed forming force in forming process, which can control product quality better;

2)補(bǔ)償主軸變形

Compensate main spindle’s transformation;

3)補(bǔ)償模具磨損

Compensate wear tooling

下主軸前后調(diào)節(jié)Forward & Backward Adjustment of Lower Spindle

下主軸水平前后調(diào)節(jié)機(jī)構(gòu)，取代了原來加墊片的調(diào)整方法，更加便于調(diào)整模具。旋轉(zhuǎn)中軸螺栓（3）帶動鏈輪（2）轉(zhuǎn)動，鏈輪帶動齒套（4）旋轉(zhuǎn)，齒套（5）通過螺紋運(yùn)動推動下主軸（2）移動，可以方便而又均勻的實(shí)現(xiàn)下主軸（2）上的型輥前后調(diào)整，取代了原來加墊片的調(diào)整方法，大大的提高了模具調(diào)整效率，降低了因調(diào)整片不合適，或長時間使用失效的問題。

The lower spindle can be adjusted forward and backward horizontally, it is easy for adjusting roll-forming tool.

Attached below drawing to show operating principle, its adjustment process is:

Turning the bolt 3 of middle axle to drive the chain wheel 2 -> and chain wheel drive gear sleeve 4 and gear sleeve 5 -> to power the lower spindle 2 moving by screw thread -> for achieving forward and backward adjustment of forming roller which mounted with lower spindle 2.

主軸轉(zhuǎn)速的調(diào)整 Adjustment of main spindle’s rotation speed

主軸采用液壓馬達(dá)驅(qū)動，液壓馬達(dá)安裝在成型機(jī)的后面，通過萬向節(jié)與主軸相連，上下液壓馬達(dá)分別驅(qū)動上軸與下軸向左右不同方向旋轉(zhuǎn)，調(diào)整液壓馬達(dá)回油口節(jié)流閥來改變上下軸轉(zhuǎn)速，使之上下輥模接觸工件時保持線速度的一致，防止劃傷工件與輥模。

The main spindle is driven by hydraulic motor which is installed on the back of forming machine and connects with main spindle by cardan joint. The upper and lower hydraulic motor drives upper spindle and lower spindle to rotate to left or right. Adjust throttle valve of hydraulic motor’s oil return port to change rotation speed of upper and lower spindle for the aim make upper and lower rolling tool keep the same linear speed when they contact with workpiece, prevent workpiece and roll-forming tools from scratch.

側(cè)導(dǎo)向的調(diào)整 Adjustment of side guide device

側(cè)導(dǎo)向用于保持輪輞在成型過程中的軸向位置，以及使輪輞中心處于模具中心之下，導(dǎo)向輪的位置可以根據(jù)工件狀況進(jìn)行調(diào)整。

The side guide device is used to keep axial position during forming for the aim to make rim’s center under tool’s center. Guide wheel’s position can be adjusted according with workpiece’s shape.

側(cè)導(dǎo)向裝在上主軸兩側(cè)，每個側(cè)導(dǎo)向帶有滑道沿直線運(yùn)動，為液壓驅(qū)動。

The side guide device is installed on two sides of main spindle. Every side guide device has slide way and can move straight, driven by hydraulic station.

側(cè)導(dǎo)向的啟始點(diǎn)和結(jié)束點(diǎn)通過手輪可調(diào)，每個側(cè)導(dǎo)向的上下均有接近開關(guān)作為控制單元。

The start point and end point of side guide can be adjusted by hand wheel. Every side guide has proximity switch on top and bottom as control unit.

工件上下料裝置的調(diào)整Adjustment of loading/unloading device

上下料裝置高度的調(diào)整，根據(jù)工件直徑的大小來調(diào)整到合適的高度，可通過轉(zhuǎn)動升降的絲桿來完成。

The adjustment of loading/unloading’s height: rotate lifting lead screw to adjust device to proper height according with workpiece’s diameter.

工件推動到位的調(diào)整，可調(diào)整輥動料架前后的位置來完成。工件推到位后，輥動料架下部有鎖緊裝置，以穩(wěn)定料架的位置，并有一行程開關(guān)接通發(fā)訊。

Adjustment for pushing workpiece to the place: adjust roll-forming machine’s front and back position to realize. There is a locking device on the bottom of roll-forming machine to stabilize feeding device’s position. It also has a stroke switch to transmit signal.

拆卸型輥的推料裝置Push-ring for Dismounting Roll Forming Tool

在上下主軸（1）和（2）的根部都設(shè)計有推料環(huán)，通過油嘴注入干油，依靠油槍壓力推動推料環(huán)向前，從而推動主軸上的型輥向前有限的滑動，為順利拆卸型輥創(chuàng)造有利條件，便于快速拆裝型輥，提高了效率。

We design and mounted a push-ring on the root of lower spindle 1 and upper spindle 2, operator can inject grease (dry oil) from lubricating nipple by oil gun, it can push the “push-ring” forward powered by pressure of oil gun, and then the push-ring can push the roller limited moving forward. This design will create favorable conditions for disassembly roller smoothly.