The YCK-500T-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): 1658mm × 1855mm × 2900mm
2. Total weight: 7.5 tons
3. Machine motor power: G1 model (11KW), G2 model (15KW) - Recommended power supply line is 6mm2
4. Cooler cooling water interface size and cooling water flow rate: Interface size ZG1″; Maximum cooler water flow rate: 100L/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, slow approach to workpiece, and fast return, greatly improving machine efficiency.
2. The machine also has upper and lower die feeding functions, suitable for pressing processes under various conditions.
III. Machine Operation:
1. Start the motor (pay attention to 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, press the corresponding jog button, and the text function of that button can be realized. When the button is released, it automatically stops 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 the semi-automatic cycle state, and stops after completing one action cycle. Die selection: selecting "off" means the die does not work, selecting "upper die" means the upper die works, and selecting "lower die" means the lower die works.
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, and no adjustment is necessary during normal production. 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. Adjustment of the pressure relay: The pressure relay adjusts the pressing pressure during production. Clockwise rotation increases the pressure, and the increase can be read on the pressure gauge. When the pressure reaches 25MPa, the main cylinder has reached 500T pressure. At this time, 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 to work. At this time, the pressure relay cannot send a signal (that is, the main cylinder cannot automatically ascend). Then slowly tighten the overflow valve handle until the pressure reaches the pressure set by the pressure relay (that is, 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 machine's 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 oil, 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 oil, 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 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 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 oil, 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 oil, and reinstall it. If the handle is loose, tighten it until it is fast.
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 fuel.
② Check if the oil level is too low, causing air intake.
③ Check if the oil suction pipe is leaking.
VI. Machine Safe Operation and Maintenance Instructions:
1. Safe operation of the machine
a. Those who do not understand the machine's structure, performance, and operating specifications must not operate the machine.
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 machine's electrical equipment must be firm and reliable.
f. During operation, the safety light curtain must be adjusted to the appropriate height 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. Generally, it should 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 changed 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 substance, 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 daily production.
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 column must be wiped clean and sufficient lubricating oil added.
⑼ Maintenance and maintenance of the safety light curtain:
a) After installing a new mold, check if 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) Check the safety light curtain every time the machine is started. When the main cylinder is descending, check whether the light curtain causes the main cylinder to immediately return. Only operate after confirming that it is normal.
c) Regularly wipe dust off the housing and optical filter with a clean cotton cloth and water; check if the bracket and interface are firm.
Note: A malfunctioning safety light curtain can lead to personal injury. No one should remove the safety light curtain.
⑽ Before starting the machine every shift, add cooling water to the cooler (Note: The cooling water flow rate must not exceed 100L/min).