成功案例
描述
一、產品用途 Product Application
本機主要適用于棉紡廠、軋花廠的各種原棉、下腳棉的打包、捆綁處理，由人工將棉花裝入機內進行打包，也可用于廢品等其它軟貨物的打包。機器可根據使用單位場地條件靈活搬運、放置，操作使用方便。
It is mainly used to bale cotton waste in a cotton mill such as card sweeps and flat strips, which can be put into this machine manually and then baled, also this machine can be used to bale the wastes and other soft materials. This machine, small in size, light in weight, easy in mounting and operating, with better working conditions and reduced labor intensity.
二、主要規格 Main Technical Parameters
|
項 目 Item |
單 位 Unit |
內 容 Content |
備 注 Note |
|
包形尺寸 Baling size（L×W×H） |
mm |
1000×500×800 |
包形尺寸可定制 |
|
成包重量 Bale weight |
Kg |
80-100 |
棉花 |
|
額定工作壓力 Rated baling Pressure |
MPa |
10 |
|
|
電機功率 Overall Power |
Kw |
7.5 |
|
|
油缸行程 Travel distance of Oil cylinder |
mm |
1000 |
|
|
外形尺寸 Equipment outer size |
mm |
2100×620×3300 |
長×寬×高 L×W×H |
|
整機重量 Total Weight |
Kg |
1200 |
|
三、結構特點 Structure and Function
3.1本機主要由打包機架、液壓系統及電氣控制系統等三大部分組成。
3.2機架、門、壓棉板等組件主要由槽鋼和鋼板焊接而成，其中機架采用22#槽鋼焊接而成，強度高、不變形。獨特的鎖門裝置偏心結構，穩固可靠，易于操作。
3.3油缸活塞桿與壓棉板用螺栓緊固聯接，經導向桿導向后在打包箱內作上、下運動，壓緊物料。導向桿采用Φ60mm無縫鋼管，有效避免壓棉板因喂棉不均勻引起的傾斜，保護油缸活塞桿。
3.4液壓油箱部件安放在打包機架右側，用兩根高壓軟管分別聯接機架上油管和油箱的進出口。
3.5油缸活塞桿上下運動由手動換向閥控制，換向簡單可靠。
3.6液壓系統采用雙聯齒輪泵供油，能耗降低60%。
3.1 This machine is combined by mechanical, hydraulic and electrical parts; with high automation and easy operation.
3.2 Framework, door, cotton press board, etc, are welded by channel steel and steel sheets, framework is welded by 22# channel steel, with high strength, no distortion. Unique lock structure is stable and reliable, easy to operate.
3.3 Piston rod inside the oil cylinder and cotton-press board is connected by bolts firmly, guided by guide rod, travels up and down inside the baling framework, presses the target. Guide rod is made of Φ60mm seamless steel tube, can effectively avoid the slant of the cotton-press board due to uneven feeding of cotton, to protect the piston rod of oil cylinder.
3.4 Oil tank is put at the right side of framework, is connected to oil tank by input and output oil pipes.
3.5 The up and down movement of piston rod of oil cylinder is controlled by hand-operated direction valve, simple and reliable.
3.6 Hydraulic system, with Double gear pump, can reduce the energy consumption by 60%;
四、操作方法 Operation Instruction
打包前先關閉并鎖緊下部各門，由人工將物料均勻加滿打包箱。壓棉時，加棉口門必須關閉鎖上，確保安全操作。在換向閥手柄處于中間位置時空載起動油泵，扳動換向閥手柄，使壓棉板下降，將物料壓緊，反向扳動換向閥手柄，使壓棉板上升到頂部，再將換向手柄撥至中間位置，使油泵卸荷。以上過程重復幾次，待棉包成形后，適當上升壓棉板并定位，打開打包箱門，然后適當下降壓棉板壓緊棉包，并將換向手柄處于中間位置，即可用鐵絲捆綁棉包，最后使壓棉板上升到頂部，換向手柄恢復至中位，松開側門，用力把棉包推出打包箱，一個打包過程結束。
Before the baling process, the lower doors should be closed and locked, material is fed manually into the box. During the cotton press process, the cotton feeding door should be closed and locked, to make sure safety. Start the Oil Pump without load when the handle of direction valve at the middle position, turn the handle to move down the cotton-press board, and firmly press the material; then turn the handle of direction valve to the opposite direction, the cotton-press board can be moved to top position, then turn the handle of direction valve to the middle position, un-load the oil pump. Repeat the above movements several times, till the bale is formed, move up the cotton-press board slightly, and open the door of bale box, then move down the cotton-press board again to press tightly on the bale, turn the handle of oil direction valve to the middle position. After using the steel wires to bind the bale, move up the cotton-press board to the top position, turn the handle to the middle position to unload, open the side door, push out the bale, one baling process is finished.
五、安裝及調試 Installation and Debug
5.1 為便于運輸和安裝，打包機出廠前已把油缸和機架分離。用戶在機器定位后，應校正機器水平，使油缸垂直水平。根據說明書和機器處形圖，將油缸端法蘭與機架頂部的油缸座板用8只M16×90六角螺栓緊固聯接，活塞桿端法蘭與壓棉板用6只M16x50六角螺栓緊固聯接，工進和工退油管與油缸上下端管接頭緊固聯接，注意接頭處應墊上24x3.1密封圈。最后裝上導向桿,導向桿和導向桿座各部件螺栓需擰緊，并定期檢查該部件。
5.2 安裝前應先檢查油管接頭和控制閥是否有松動，油箱內是否清潔，然后根據油管編號，用高壓油管將閥座油管接頭和機架油管聯接。
5.3 將清潔液壓油約150升加入油箱內至油標中位線。推薦使用46#抗磨液壓油。
5.4 換向閥手柄處于中位，啟動油泵電機，從上往下看電動機軸應順時針方向轉動。
5.5 機器出廠時各控制閥壓力已調定，如需重新調節，可在機內有棉包、壓棉板頂位時，逆時針松開壓力表開并手輪和溢流閥調節螺栓，使壓棉板降至最低位置，此時先調節型號為EURG2-06-CV-13卸荷溢流閥至10MPa，在上升壓棉板的同時，調節型號為EURG2-16-BV-B卸荷溢流閥至2MPa,壓棉板應上下往復幾次，壓力表顯示10±0.5MPa就可以關閉壓力表開關并擰緊溢流閥手輪的鎖緊螺母，調試完成。
5.1 For convenience of transportation and installation, oil cylinder and framework are separated before packaging. User need to adjust the level of machine after which is put on position, to make sure the oil cylinder is vertical. Under the instruction of Product Manual and Outer Figure of Equipment, connect flange of oil cylinder to upper framework by 8 pcs of M16X90 hexagon bolts , connect the flange of piston rod with cotton-press board by 6 pcs of M16x50 hexagon bolts. Oil pipes of forward and backward should be connected to the upper and down joints accordingly, make sure the 24x3.1 seal ring is inside. At last, guide rod should be assembled tightly, every bolt should be tightened, periodical check is necessary on these components.
5.2 Check if there is any loosing on every oil connector and valve before installation, whether oil tank is clean, then connect the valve connectors with oil pipes from framework according to the pipe identification numbers.
5.3 About 150L clean hydraulic oil need to be poured into the tank, up to the middle mark line of oil pointer. 46# anti-corrosion hydraulic oil is recommended.
5.4 Make sure Direction Valve is at the middle position, start motor of oil pump, the axle of motor should run clockwise when being looked down;
5.5 The pressure of every valve has been set before packaging, no need to adjust again. If it’s necessary to adjust, only when there is bale inside, cotton-press board at the top position, loosen the hand wheel of pressure indicator anti-clockwise and adjust bolts of overflow valve, lower down cotton-press board to the lowest position, then adjust the Overflow Valve EURG2-06-CV-13 to 10MPa, adjust the EURG2-16-BV-B to 2MPa while the cotton-press board is going up, cotton-press board would go up and down several times, when pressure indicator indicates 10±0.5MPa, pressure indicator switch can be shut off and the locknut of overflow valve handle wheel can be tightened too, the debug is finished.
六、維護保養及常見故障排除 Maintenance and trouble solving
6.1 每班結束，應做好機器的清潔工作，在門鎖、鉸鏈處應定期加油潤滑。 每星期檢查液壓系統工作壓力一次，如有壓力變化，應及時調整。油液工作溫度范圍為5-80°C，定期檢查油液損耗情況和油液性能，及時添加或更換。一般情況下新機運行3個月后應重新換油，以后每年換油并清洗油箱一次。
6.2 常見故障及排除方法
6.1 After every shift, equipment should be cleaned, lock and hinges should be applied lubrication periodically. Oil pressure of hydraulic system should be checked once per week, which should be adjusted in time if any change. Oil temperature range is 5-80 ℃, oil depletion and oil performance should be checked periodically, and added or replaced in time. Normally, new machine should be replaced all the oil after running for 3 months, then once per year, and oil tank should be cleaned once per year.
6.2 Common malfunctions and solving methods:
|
現象 Phenomenon |
原因 Causes |
排除方法 Solving method |
|
液壓系統達不到額定壓力 Oil pressure lower than the system rated. |
1、溢流閥失壓 Overflow valve lost pressure |
1、調節或清洗溢流閥 Adjust and clean the overflow valve |
|
活塞桿出現沖擊爬行現象 Piston rod has shock and creeping phenomenon |
1、液壓缸中進入空氣 Air enters cylinder |
1、活塞桿上下運動多次排除空氣 Move the piston rod up and down several times to eliminate air |
|
油缸漏油 Oil leakage of cylinder |
1、密封件損壞 Seal ring damaged |
1、更換密封圈 Replace seal ring |
七、主要液壓元件技術規格表(FB1) Hydraulic system specifications (FB1)
|
型號名稱 Type/Name |
額定壓力MPa Rated Pressure MPa |
額定流量 Rated Flow |
缸徑 Cylinder Diameter |
最大行程 Max.Stroke |
|
雙聯齒輪泵 Double Gear Pump |
14 |
62 |
|
|
|
手動換向閥 Manual Direction Valve |
31.5 |
|
|
|
|
卸荷溢流閥 Unloading Overflow Valve |
3.5-14 |
|
|
|
|
卸荷溢流閥 Unloading Overflow Valve |
7 |
|
|
|
|
液壓油缸 Cylinder |
16 |
|
125 |
1000 |
八、附圖 Appendix Figures:
1 機器外形圖 Outlook of the machine
2 液壓原理圖 Hydraulic Principle Figure
3 電氣原理圖 Electricity Principle Figure
4 油缸裝配示意圖及裝配說明 Oil Cylinder Assembly Instruction Figure
打包機油缸拆、裝步序 Assembly and Disassembly sequence of Oil Cylinder
拆裝順序：
一 外部Φ125軸用擋圈卸下。
二 拿出擋圈。
三 用錘輕敲缸套頭，將缸套頭推至過擋環，并取出擋環。(三塊)
四 將安裝環裝入油缸擋環環槽內。(應注意按裝環內徑不能大于油缸內徑)
五 人力拉動活塞桿，利用活塞桿上的活塞拉出缸套頭。
六 在外換好YX型軸用油封d70,O型密封圈Φ125x5.7=2件，Φ80x5.7(注意YX型d70油封不能裝反)
Disassembly sequence:
1. Take off the axle outer check ringΦ125;
2. Take off the check ring;
3. Tap the cylinder jacket, push the jacket to over the block rings, and take off the block rings (3 pcs);
4. Put the installation ring into the grooves inside the cylinder (Make sure ID of the installation ring should not be oversize than ID of cylinder;
5. Pull piston rod by man power, pull out the cylinder jacket by piston;
6. Change the YX type rod-seal d70, O type seals Φ125x5.7=2 pcs, Φ80x5.7.( Make sure YX type seal is the right direction);
按裝順序：
一 將活塞桿(包括活塞)一體裝入油缸至2/3處。
二 將調換好密封圈的缸套頭裝入油缸，不能裝斜。特別注意內、外徑的密封圈。
三 用錘輕敲缸套頭，推至過按裝環。
四 取出按裝環，裝上擋環。
五 拉出活塞桿，使缸套頭與擋環頂住。
六 裝上擋圈，及軸用擋圈(軸用擋圈應全部到位)。
七 推入活塞桿，將油缸裝上機器。
Assembly sequence:
1. Put the piston rod (with piston) inside the 2/3 position of cylinder;
2. Put the piston jacket with replaced seal ring inside the cylinder without slanting, pay special attention to the seal rings at ID and OD;
3. Tap the cylinder jacket lightly, move it outside the check ring;
4. Take off the check ring, install the block rings (3 pcs);
5. Pull out piston rod, let the cylinder jacket blocked by block rings;
6. Install the block rings, and axle block ring (all in position);
7. Push in the piston rod, assembly the cylinder to the machine;
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