The YCK-200T-G hydraulic press is a new high-speed hydraulic press launched by Hongde Company, featuring high speed and precision. This tutorial is for the on-the-job training of customer employees when purchasing a new machine.
I. Basic Machine Knowledge:
1. Outline dimensions (length × width × height): 1200mm × 960mm × 2000mm
2. Total weight: 2.5 tons
3. Machine motor power: 7.5KW - Recommended power supply lead-in wire: 6mm2
4. Cooler cooling water interface size and cooling water flow rate: Interface size ZG3/4″; Maximum cooling water flow rate: 60L/min. The cooler water flow rate must not exceed this value.
5. The machine must be connected to cooling water during operation to ensure normal oil temperature (oil temperature ≤ 55℃).
II. Basic Machine Functions:
1. The machine has functions of fast idle stroke, slow approach to workpiece, and fast return stroke, greatly improving machine efficiency.
2. The machine also has upper and lower die clamping functions, suitable for pressing processes under various workpiece conditions.
III. Machine Operation:
1. Start the motor (note the motor direction - clockwise). The operator can then select the "Jog" or "Automatic" mode according to production needs. When selecting the "Jog" mode, enter the jog mode. Pressing the corresponding jog button will achieve the function indicated by the button text; releasing the button will automatically stop at the position before releasing. Therefore, the jog button is generally used when installing and debugging the mold. When selecting the "Automatic" mode, the machine enters a semi-automatic cycle state, and stops after completing one action cycle. For die clamping selection, selecting "OFF" means the die clamping function is not working; selecting "Upper Clamping" means the upper die clamping function is working; selecting "Lower Clamping" means the lower die clamping function is working.
2. During normal production, the operator only needs to press the double button.
IV. Simple Machine Adjustments:
The hydraulic device handles on the machine have been adjusted appropriately at the factory. No adjustment is necessary during normal production to avoid abnormal movements or even machine accidents.
During normal production, only the pressure relay and the pressure limiting overflow valve on the front right of the machine need to be adjusted.
1. Pressure relay adjustment: The pressure relay adjusts the pressing pressure during production. Turning the pressure relay clockwise increases the pressure, and the increase can be read on the pressure gauge. When the pressure reaches 25MPa, the main cylinder has reached 200T pressure. At this point, it cannot be increased further, otherwise it will overload.
2. Adjustment of the pressure limiting overflow valve on the front right of the machine: First, loosen the overflow valve completely, adjust the pressure relay to the required pressure (Note: Do not overload), then press the automatic double button to make the machine automatically descend and press to work. At this time, the pressure relay should not send a signal (i.e., the main cylinder should not automatically ascend). Then slowly tighten the overflow valve handle until the pressure reaches the pressure set by the pressure relay (i.e., the pressure relay can just send a signal). Finally, loosen the pressure relay completely and tighten the overflow valve nut. The adjustment is complete. After this adjustment, the mold will no longer be damaged due to overpressure, thus better protecting the mold.
V. Common Faults and Solutions:
a. The moving crossbeam slides down:
① Adjust the support valve, slowly tighten the handle clockwise until the moving crossbeam no longer slides down.
② If adjusting the support valve does not work, adjust the lifting overflow valve.
③ If adjusting both the support valve and the lifting overflow valve does not work, the support valve and lifting overflow valve should be removed, cleaned, and reinstalled into the integrated block.
④ If the support valve and lifting overflow valve still do not work after cleaning, check whether the main piston seals are aged or worn.
b. The main cylinder cannot be lifted:
① Check whether the system electromagnetic overflow valve is energized normally, whether the lifting overflow valve is normal, and whether the charging valve is open normally.
② Check whether the main cylinder pressure gauge reading reaches the pressure set by the pressure relay. If the main cylinder pressure does not reach the pressure set by the pressure relay, the main cylinder will not return in semi-automatic state.
③ Check whether the main solenoid valve is energized in the main cylinder lifting direction; whether there is a stuck valve phenomenon. If a stuck valve phenomenon is found, remove the valve core, clean the valve core and valve body with diesel, and reinstall it.
④ Determine whether the mold stripping force exceeds the lifting force of the main cylinder.
c. The main cylinder has no pressure or insufficient pressure:
① Check whether the system overflow valve is energized normally, whether there is a stuck valve phenomenon. If a stuck valve phenomenon is found, remove the valve core, clean the valve core and valve body with diesel, and reinstall it.
② Check whether the charging valve is normal.
③ Check whether the oil pump and motor are normal.
④ Check whether the main piston seals are aged or worn (Method: When the main cylinder is pressurized, touch the return oil pipe of the main cylinder lower cavity by hand. If there is return oil, it indicates that the main piston seals are damaged).
d. The motor cannot start:
① Check whether the power supply is missing a phase.
② Check whether the fuse is normal.
③ Check whether the thermal relay is activated.
e. The main cylinder does not have a fast idle stroke downward movement:
① Check whether the slow-speed electromagnetic valve is stuck. If a stuck valve phenomenon is found, remove the valve core, clean the valve core and valve body with diesel, and reinstall it.
② Check whether the sequence valve is stuck or the handle is loose. If a stuck valve phenomenon is found, remove the valve core, clean the valve core and valve body with diesel, and reinstall it. If the handle is loose, tighten it until there is a fast speed.
f. The main cylinder does not have a slow mold closing movement:
① Check if the main cylinder slow travel switch is working properly, causing the slow electromagnetic valve to be de-energized.
g. Excessive oil pump noise
① Check if the filter screen is clogged. If clogged, clean it with diesel.
② Check if the oil level is too low, causing air intake.
③ Check for air leaks in the suction pipe.
VI. Machine Safe Operation and Maintenance Instructions:
1. Safe Operation of the Machine
a. Do not operate the machine if you do not understand its structure, performance, and operating specifications.
b. It is strictly forbidden to operate beyond the maximum load (i.e., the pressure gauge shows a pressure of 25Mpa).
c. It is strictly forbidden to exceed the maximum stroke (i.e., the distance between the upper and lower molds should be less than the maximum stroke of 160mm).
d. If the machine exhibits unreliable operation, excessive noise, vibration, or serious oil leakage, stop the machine immediately and consult a professional to analyze the cause and troubleshoot the problem.
e. The grounding of the electrical equipment of this machine must be firm and reliable.
f. The safety light curtain must be adjusted to an appropriate height during use according to the actual operating conditions.
2. Maintenance Instructions:
⑴ Hydraulic oil must use the recommended hydraulic oil and cannot be replaced with other engine oil or lubricating oil to avoid damaging the hydraulic components in the hydraulic system;
⑵ The oil must be clean. It should generally be strictly filtered before being injected into the tank. The oil level must not be lower than the lower limit of the oil level indicator;
⑶ The oil should be replaced once a year. For the first use of new oil, it should be completely drained and filtered after two months of use, and the oil tank should be cleaned before the filtered oil is injected into the tank. If the oil is found to be emulsified, cloudy, or has a sticky, gummy appearance, replace it with new oil immediately;
Note: The cleanliness of the hydraulic oil directly affects the performance of the machine and may cause machine damage and personal injury.
⑷ The oil filter at the oil pump suction port should be removed and cleaned with gasoline or kerosene every three months. If holes are found, replace the filter with a new one;
⑸ Long-term operation will cause mechanical wear of the valve core. The valve core in the hydraulic components must be checked frequently. If worn, the hydraulic valve should be replaced.
⑹ Electrical components generally have a mechanical or electrical life of 400,000 to 4,000,000 cycles. It is recommended to replace the relay approximately every six months and the PLC every one to two years, depending on the daily production volume.
⑺ Regularly check whether the power voltage is normal (must not be lower than 370V). Abnormal voltage directly affects the service life of electrical components.
Note: The service life of hydraulic and electrical components directly affects machine safety and even personal safety.
⑻ Before starting the machine every shift and after shutting down the machine every shift, the column must be wiped clean and sufficient lubricating oil must be added.
⑼ Maintenance and maintenance of the safety light curtain:
a) After installing a new mold each time, check whether the height of the safety light curtain is appropriate
(i.e., check whether both hands are within the effective protection range of the safety light curtain during normal operation)
b) The safety light curtain must be tested each time the machine is started. When the main cylinder is descending, check whether the light curtain causes the main cylinder to immediately return. Only after confirming that it is normal can work begin.
c) Regularly wipe off dust from the housing and optical filter with a clean cotton cloth and water; check whether the bracket and interface are firm.
Note: Malfunction of the safety light curtain will lead to personal injury. No one is allowed to remove the safety light curtain.
⑽ Before starting the machine each shift, cooling water must be added to the cooler (Note: The flow rate of cooling water must not exceed 60L/min).