Hydraulic Metal Shears Steel Wire Cutting Machine
Metal gantry shear is a kind of heavy hydraulic cold shearing equipment with large travel portal frame, which is used for one-time cutting of heavy scrap steel with large size and large section. Completely different from the cantilever swing shearing of the crocodile shear and the volume compression of the metal baler, the gantry shear adopts a fixed portal rigid frame and relies on the vertical main pressure shearing knife to go down vertically along the guide rail to complete the cutting. It is the core main equipment of the large scrap steel processing base and the raw material pretreatment workshop of the iron and steel plant. It mainly focuses on continuous, large-tonnage and heavy scrap steel volume reduction.
Working Method:
1. Feeding stage: heavy scrap steel and scrapped components push super-long and super-large workpieces to a shearing workbench through a hydraulic material pushing trolley, and the workpieces pass through a shearing edge inside a gantry frame;
2. Pre-compaction stage: that equipment is provide with a plurality of groups of hydraulic material press mechanisms, which are pressed and locked from a plurality of point above the workpiece, and the multi-layer stacked and irregular heavy scrap steel is firmly compacted on the worktable surface, so that the warping and bouncing of the material are eliminated, the displacement of the workpiece at the moment of shearing is avoided, and the risk of tool collapse is prevented;
3. Vertical shear stage: that main oil cylinder drives the heavy shear tool rest to vertically feed downwards at a uniform speed along the precision guide rail on both sides of the frame. The upper and lower alloy knife edges exert a huge concentrated load on the metal section to break the thick steel plate, billet and heavy section steel at one time. The shearing process is linear downward pressing, the stress is uniform, and the eccentric load resistance is far superior to that of a cantilever crocodile shear;
4. Cutter rest return and continuous feeding: After a single shearing is completed, the main cylinder drives the cutter rest to lift and reset, and the pushing trolley continues to push the material forward to enter the next shearing cycle.
Complete machine structure:
1. Door-type integral welding frame
The frame of the whole machine is an integrated portal structure with double columns and upper beams, which is welded with super-thick low-alloy high-strength steel plates. Carry out integral stress relief annealing and flaw detection after welding to eliminate welding residual stress. The frame bears hundreds of tons of repeated impact loads, and the column will not bend or twist under long-term heavy load conditions. The bottom of the frame is rigidly connected with the embedded parts of the foundation, and the reinforced concrete foundation must be poured for the heavy-duty machine to ensure the anti-impact stability of the whole machine. A precision guide slideway is processed on the inner side of the column to restrict the motion track of the tool rest.
2. Tool rest assembly and guide mechanism
The tool rest is a moving part bearing the upper blade, and wear-resistant guide sliders are installed on both sides and clamped in the guide rail of the column to ensure that the tool rest can only move vertically up and down in a straight line and eliminate lateral deviation. The guide pair is made of self-lubricating wear-resistant alloy to reduce the wear of high-speed reciprocating motion. The knife rest is rigidly connected with the piston rod of the main oil cylinder to completely transmit the thrust of the oil cylinder to the shearing cutting edge.
3. Shear blade assembly
The blade is made of high-toughness H13 and Cr12MoV alloy tool steel, and is subjected to quenching and tempering compound heat treatment, so that both high hardness and impact toughness are taken into account. The blade adopts a sectional combined structure, and when the local cutting edge is damaged, the damaged blade section can be independently replaced without integrally replacing the whole set of blade, thereby reducing the maintenance cost. The blade gap can be finely adjusted by the gasket to adapt to different thicknesses and different materials of steel, optimize the quality of the incision, and reduce the chipping and burrs.
4. Hydraulic pushing and multi-point pressing system
-Hydraulic pushing trolley: It is installed at the tail of the workbench and driven by an independent pushing cylinder. It can push several tons of long scrap steel to feed continuously to realize continuous feeding. The workbench surface is paved with wear-resistant steel plates to bear the dragging friction of the workpiece.
-Multi-point hydraulic pressing cylinder: Multiple groups of independent pressing cylinders are arranged along the front and back of the knife edge, and the multi-point synchronous pressing is carried out. For the heavy waste materials with uneven height and multi-layer stacking, the sectional locking is realized. It is the key structure for the gantry shear to cut large parts safely.
5.Hydraulic power system
This metal shear is equipped with a large-flow high-pressure hydraulic pump station and a multi-plunger pump combination for oil supply, which can realize the dual-speed logic of low-pressure rapid feed and high-pressure shearing: the tool rest moves rapidly at low pressure when it goes down in idle travel, and automatically switches to high pressure at the moment of contacting the workpiece, taking into account the operation efficiency and shearing force. Large models are equipped with independent water cooling system as standard, which can meet the requirements of 24-hour continuous production and inhibit the pressure attenuation caused by the increase of oil temperature for a long time. The valve group adopts integrated large-diameter hydraulic valve, which has fast response and can withstand the impact of large flow. Local motor drive can be selected as required, and diesel power unit can be configured for a few special working conditions.
6. PLC automatic electric control system
The whole machine adopts programmable PLC controller and dual operation mode of touch screen + entity button. It supports three modes: automatic continuous cutting, semi-automatic single cutting and manual inching debugging. The system can set the cutting stroke, pressing pressure and pushing speed, and has built-in overload alarm, stroke limit and reverse cutter lifting protection. Equipped with safety grating, protective fence and emergency stop interlocking device, once the personnel enter the dangerous area by mistake, the equipment will be locked and stopped immediately. The data panel can record the cumulative shearing output and the running time of the equipment, which is convenient for the production management of the factory.
Key points of refined operation and maintenance:
1. Maintenance of rack and guide rail: clean iron filings and sundries inside the guide rail every day, and regularly fill special lubricating grease; regularly check the anchor bolts, which will be loosened due to heavy load impact, and need to be tightened periodically to prevent the displacement of the rack.
2. Blade maintenance: check the fastening bolts of the blade before each operation; grind or replace the cutting edge in case of breakage and passivation; strictly control the blade clearance, which is easy to cause curling and accelerate the damage of the blade.
3. Maintenance of hydraulic system: replace the hydraulic oil according to the operation hours, and regularly clean oil tank and filter element; check all high-pressure pipeline joints, which are prone to loosening and leakage under impact load; regularly clean scale of the cooler for water-cooled models to ensure the heat dissipation efficiency.
4.Material pushing worktable and material pressing mechanism: the wear-resistant plate of the worktable shall be replaced in time if the wear exceeds the standard; the seal of the material pressing cylinder shall be checked to prevent the material locking failure due to insufficient pressure.
5. Electrical and safety system: regularly check the safety grating and travel limit sensor, clean metal dust in the electric control cabinet; check the PLC signal line to prevent the signal false alarm caused by dust and vibration.
