Operation manual. Single long billet hot shear furnace

Transcription

1 Operation manual Single long billet hot shear furnace 0

2 Content 1 Safety instructions Structure characteristic and working principle Technical paremeters Specification table Operation of the machine Daily maintenace and management Breakdown maintenance Electric schematic diagram Combustion schematic diagram Hydraulic schematic diagram

3 For your personal safety, please read the operation manual carefully before you operate the machine. You should also know the application and limits, including the relevant potential dangerous of this machine very well. 1. Safety instructions 1.1 Safety regulations 1) Common safety regulations a.know the machine b.keep the working area neat and tidy. Mussy working area and working table may cause to accident. c.non-professional people please keep away All of the visitor must be kept away the safety distance in the working area. d.don t operate the machine forcibly. Let the machine run safely under the designed speed. Use the correct tools, and do not operate the machine or additional device forcibly. e.appropriate dressing Please avoid wearing loose clothing, gloves, necklace, bracelet or ornaments, which are easy to be drawn into the moving parts of the machine. It is suggested to wear antiskid shoes and head cap that can wrap the long hair. f.don t maintain the machine under the working state. The machine should be maintained properly, but do not execute the maintenance while the machine is charged or running. g.grounding the machine correctly Before installing the machine, please use the conductor to build a reliable grounding to prevent the harm from unexpected electricity leakage. 2

4 h.maintenance after outage Please make sure to cut off the power of the machine before maintaining and replacing the spare parts or assembling and reassembling the motor. i.use the suggested spare parts indicated on the manual. The buyer should only use the fixed configuration and wearing parts specified by the seller. j.operation supervision Please turn off the machine in time to avoid it running alone when the operator leaves. k.ventilation Combustible gas may generate during the runing of machine, it s suggested to add the chimney according to the real situation, and keep a good indoor ventilation. 1.2 Warning sign The machine has the following warning signs attached to it to ensure the correct and safe operation These warning signs are attached on the machine in order to indicate the dangerous point which may happen to the operator Be ensure to keep these warning sign in mind, and cause the attentions from other people to ensure the safety Don t remove any safety signs from the machine Recognition of the safety sign: WARNING 3

5 CAUTION Shock hazard 4

6 Be careful of the operation 2 Structure characteristic and working principle Single log hot shear furnace is used in the preceding process of aluminum extrusion, mainly for billet heating. It combines the new technology of gas spray burning and enhanced heating, hydraulic hot shearing, etc. This furnace has the advantages of flexible production, high automation, good operation circumstance and low energy consumption. So the hot log shear furnace is widely adopted by many manufacturers in a short time. 2.1 Structure characteristic Billet storage table and feeding table Billet storage table - Aluminum billet center and the longitudinal centerline of the furnace is parallel. The storage table is a gravity-type hydraulic cylinder used for 5

7 loading and unloading long billets. Its welded structure is stable support frame and can withstand heavy weight. Billet feeding table It is used to receive aluminum billet one by one from the storage table and deliver it into the furnace to ensure the continuity of production. As long as the billet is sent to the feeding table, the delivering process will start automatically. Transmission inside furnace Billet moves on stainless steel rollers mounted on a stainless steel stand, whose thermal expansion has been fully considered in the design Hot spray heating furnace High burning efficiency spray preheating technology The hot spray preheating section of the heating furnace consists of a countercurrent heating system, which is professionally designed. It achieves efficient preheating by high-speed impacting in furnace cavity that has pressure control. Combustion air preheating system The system can preheat combustion air to and reduce the exhaust smoke temperature to lower than 150. It can also speed up the heating rate and reduce gas consumption by 10%, thus achieves remarkable energy saving effect. Temperature uniformity control Automatic PLC temperature control program, the temperature uniformity can reach ± 9. To accurately measure the temperature of every section of the billet, we adopt Japan SMC integrated sliding cylinder drive thermocouple probe. The temperature measurement results are displayed on the human-computer interface. 6

8 Furnace chamber with pressure at the furnace mouth, which is good for thermal efficiency and control, forms an air barrier that can separate the preheated spraying hot air and cold air. Thus can not only reduce heat loss and waste of energy but also can ensure the spray temperature. Equipment reliability The transmission roller components of furnace body (roller, roller sleeve, roller shelf) are made with special stainless casting steel, whose normal average service time are more than 3 years. The design of the gas pipeline has pressure regulating and monitoring, flame surveillance, automatic blow and sweep, etc, all the valves and control devices can ensure the safety factor of design has been reached Hot shear and hydraulic system overview Shear frame structure Made from machined steel plate, it is bolted and rabitted together to form a house for the fixed clamping shear rings, and guides for the moving shear block. The frame is bolted to a fabricated steel base plate, fixed directly to the floor with foot bolts. The moving shear block has bronze liners bolted on and is connected to the shear cylinder by a floating block, minimizing non-axial loading on the shear cylinder rod. Shear ring The shear rings are made from H13 tool steel, they are hardened and tempered. The entry side "clamping" ring consists of two halves, it can be adjusted from left to right sliding, and it is fixed to the steel housing. The clamping cylinders engage in dovetails in the sides of the rings, pulling the rings back to register faces on the housing to give the correct clearance when "open". The rings are retained by plates bolted to the housing and can be removed and replaced without dismantling the clamp 7

9 cylinders within about 1 and half hour. The entry side is tapered to guide the log in. Operation of shearing The shear is matched with the billet heating furnace, the typical cycle takes 28 seconds, including furnace door opening, shearing, billet push back, and furnace door close. 2.2 Heating principle Adopts the LPG or nature gas as the fuel to heat the workpiece. The LPG or nature gas is adjusted to 4~8 Kpa by the reducing valve, the combustion air mixed by the mixer then spray out from the burner, after igniting by the ignition flame of burner to reach heating the workpiece; it is due to the transformer outputs high voltage to produce the flame to ignite, and the flame detector to monitoring the ignition steps succeed or not. This equipment is designed with multiple safeguard, the pressure switch detect the gas pressure, combustion air pressure, if the pressure fails to meet the requriements, the system will not work normally. 3. Technical paremeters 8

10 No 4inch 5 inch 6 inch 7 inch 8 inch 9 inch 10 inch 12 inch 13 inch 14 inch 16 inch φ102mm φ127mm φ152 φ178 φ203 φ228 φ254 φ305 φ330 φ356 φ406 Billet heating furnace 1 Billet weight/m 22KG 34KG 49KG 67KG 88KG 110KG 137KG 198KG 232KG 270KG 350KG 2 Extrusion press 600T 1000T 1400T 1650T 2000T 2500T 3000T 3600T 4500T 4500T 5500T 3 Bille length 6000mm 6000mm 6000mm 6000mm 6000mm 6000mm 6000mm 6000mm 6000mm 1200mm 1200mm 4 Typical alloy Efficiency Workpiece(mm) φ102*400 φ127*500 φ152*600 φ178*750 φ203*900 φ228*900 φ254*1000 φ305*1200 φ330*1200 φ356*1200 φ406*1200 Heating speed 60pc/H 60pc/H 50pc/H 50pc/H 40pc/H 30pc/H 20pc/H 17pc/H 15pc/H 12pc/H 10pc/H 1min/pc 1min/pc 1.2min/pc 1.2min/pc 1.5min/pc 2min/pc 3min/pc 3.5min/pc 4min/pc 5min/pc 6min/pc Max. output 1000KG/H 1000KG/H 1500KG/H 2500KG/H 3000KG/H 3000KG/H 3000KG/H 3600KG/H 4000KG/H 4000KG/H 4000KG/H 6 Max. heating temp Temp. uniformity ±9 ±9 ±9 ±9 ±9 ±9 ±9 ±9 ±9 ±9 ±9 8 Heat-up time ( ) 20min 20min 25min 25min 30min 35min 35min 40min 40min 50-60min 50-60min 9 Heating zone 3 zone 3 zone 3 zone 4 zone 4 zone 4 zone 5 zone 6 zone 6 zone 6 zone 6 zone 10 Energy consumption (Nature gas) 25m³ 25m³ 25m³ 25m³ 28m³ 28m³ 28m³ 30m³ 30m³ 30m³ 30m³ 11 Fuel Nature gas, LPG 12 Heat value Nature gas : 8400kcal LPG:23000kcal 13 Gas pipe DN50 DN65 14 Gas inlet pressure 0.7-1bar 15 Compressed air 5-8bar 9

11 4 Specification table 4.1 Model Model No. Model Power Measurement Weight(kg) 1 KB-04 33KW 22500*3600* KB-05 40KW 22000*3600* KB-06 50KW 22500*3600* KB-07 55KW 24000*3800* KB-08 78kw 24000*3800* KB-09 80kw 25500*3800* KB-10 95kw 27000*3800* KB-12 95kw 28500*3800* KB-13 95kw 29500*3800* KS-14 40kw 22000*2600* KS-16 40kw 23000*2600* (Note: All of the specifications, sizes and design features are subject to the agreements on the contract.) 4.2 Structure view of product 10

12 4.3 Outline view of product (1) Overall view (2) Hot shear 11

13 5. Operation for start up the machine 5.1 Check before starting up the machine Before turning on the power supply, please check whether the cool water switch of the circulating blower is open or not, please also check the water cooling base lubricating oil and tension condition of the circulating blower belt. The lubricating oil is 30# machine oil Please make sure that the pressure of compressed air connected to the machine is Mpa (4-6Bar) Please check the conditions of the thermocouple is normal or not, and the concordance of the pinpoint, the tail wiring and the lubrication of the rodless cylinder guide rail are good or not, etc Please check all the rotating parts, hot shear and transmission mechanism, and make sure that they are not stucked by foreign materials Please check whether the emergency stop switch and pause button are resetted or not. 5.2 Operation for starting up the machine Heating-up: Turn on the main power switch in the control cabinet, close all the breaker, the touch screen will be electrified automatically, and display the main page Set the temperature value on the main page of the human-computer interface. For the details, please refer to the commentary for the operation of touch screen Start the circulation blower ( it will enter into the process of blowing & sweeping and leaking detection automatically for about 60 seconds, do not make any operation during the blowing and sweeping), combustion blower by turns; 12

14 After the blowing & sweeping and leaking detection, start the small fire(ignition) of each zone through the touch screen, the small fire switch on the screen display as red to show the success of the ignition. (If the ignition of small fire fails, the fault lamp will shine, please press the " Confirm" button on the screen lightly and turn off the small fire switch of the fault zone, and then press the small fire switch (ignition) once again) After finishing the ignition, please light up the big fire to warm up Billet discharge and cutting Under normal conditions, when the billet temperature reach the setting value, please place the automatic shearing switch to "ON", and press switch of once cycle, and the machine will finish one shearing cycle automatically If there is fault during the billet shearing cycle, please check the situation and press the emergency stop or pause button immediately so that to stop or break off the cutting. The next shearing can be proceeded only after finding out the fault cause and solving the problem. Warning: If the billet end face is not smooth, or billet bend, please do not put it inside the furnace, because they will make the billet go to the wrong rail inside the furnace and damage the furnace chamber under critical situation. 5.3 Machine closing 关闭加热开关 ( 大火 ); Close the heating switch (big fire) Close small fire(ignition) switch of each zone; 13

15 5.3.3 Close the blower after 30 minutes Close the main power Warning: When the furnace temperature is high (more than 400 ), please delay the stop of the circulating blower by 30 mins, so that to avoid the billet melting inside the furnace. 5.4 Instructions for operating the touch screen The machine can work in two modes: manual and automatic, the working mode can be changed the two position selector switch on the panel. When the switch is on the side of manual position, press once cycle button will not work; when it's on the side of automatic side, the once cycle button will work. Under the automatic mode, please do not press the function button on the screen so that to prevent any fault action. 14

16 Cautions: 1. The blue button in the top of the page is for switching the screen and can be oprated at any time; 2. The function buttons on the touch screen can only be used for the operation under the manual mode. 3. The red value on the screen are changeable, the value with other color are for display only and could not be changed. 4. Please mind the force and clearance of your finger when pressing the touch screen. Attentions: Please do not touch the screen with pointed and oiled objects! Once the machine is electrified, operate the touch screen to the control page. 15

17 When the machine is working normally, please let the screen display this page, through which you can set the temperature value for each heating area and the shearing length of the billet, you can also know the present temperature conditions of each area, the remaining length of the first billet and the accumulative volume of production. At the same time, when there is a fault, the alarm screen will display the alarm information. Below is the manual screen 16

18 On this screen, all the function buttons can only work under the manual mode, and their place sequences are in accordance with the shearing order. Attention: When press the function button on this page, please make sure the shearing automatic switch on the electric cabinet is placed in the manual position! False operation will cause to wrong action of the machine! Click for checking the operation condition of the combustion system. 6. Daily maintenance and management 17

19 1)Because natural gas has the danger of inflammability and explosibility, please appoint the specialized workers to operate and maintain the machine. Be sure to check the air impermeability of gas pipeline every month. 2)Please check the gas filter to see whether it is blocked every 3 months. 3)Please regularly check the impermeability of gas valve and clean it with cotton fabric and anhydrous alcohol every 3 months. 4)Before starting the machine, please check the gas inlet pressure and gas pressure during the operation. 5)Close the general gas ball valve when production is discontinuous. When open the valve, please open 1/6 of it at first, after the gas gradually fills the gas pipe, open the valve completely. Do not open the ball valve in one step, or the gas pressure reducing valve will be damaged. 6)Be sure to check the tightness of blower belt every month; for new machine, it must be checked every week. 7)Be sure to check whether the blower cooling water is open before starting the machine. 8)Check whether the cooling water system is blocked every month. 9)Check the blower bearing and it s remaining oil amount every month. 10)Check the heating phenomenon of the blower when it s running; if overheating, please find out the reason. 11)Check the tightness of furnace door and cylinder condition every month. 12)Regularly check the pressure of compressed air and the water draining of triplet. 18

20 13)Regularly check the tightness of hydraulic pipeline. 14)When the machine it s running, please ensure the supply of gas, compressed air and cooling water. 15)Before starting the machine everyday, please check whether the air adjusting plate of combustion blower is in the suitable place. Do not close the adjusting plate for ignition, or there will be explosion. 16)Regularly check whether the flame detector is sensitive. Please replace it if there is any abnormal. 17)Regularly check whether the electrical appliance and circuit are sensitive and complete. Any abnormity, please stop and machine and repair it. 18)If some parts is operating abnormal and appearing noise, please check and repair it timely, ill operation is not allowed.the quick-wear parts and travel switch should be replaced timely. 19)Please check the lubrication condition of column of thermal cylinder and the firm degree of thermal bulb every week. 20)Regularly check up the point of thermocouple needle, because the needle goes insider of the billet to measure the temperature, so it should keep the point. 21)Small maintenance: six months to a year. Check and maintain the driven parts and valves, clean up the sundries, add lubricant and filter hydraulic oil, clean up the sundries in oil cooler. Oper the furnace cover and check the condition of insulation cotton and the flexibility of rollers inside furnace. Also check the melting loss condition of ignition gun and big combustion gun and make sure that seal ring of big combustion gun is not aging. 22)Complete maintenance: after the furnace has been used for a long time(such as 19

21 more than 5 years), it s a must to have a complete maintenance. Clean all moving parts, replace all quick-wear parts. According to the operation, update the searling parts when necessary, and reinstall, commissioning and painting. 7. Breakdown maintenances 1) Small fire ignition failure If the ignition fails for 4 or more times, please take out the ignition gun and adjust it manually, check whether the ignition components are broken;whether there is any problem of connected circuit; whether the ignition transformer is discharging; whether ignition electrode has gap; whether the combustion pipeline and air pipeline are tapped; Check the mixed proportion of air and gas. The flame adjustment must has proper stiffness, or over soft flame can easily die out. 2) Thermocouple breakage Temperature compensation wire is open circuit; the temperature measuring needle fails to measure the billet; check whether the billet in the furnace chamber is misplaced or not; check whether the thermal bulb fall off. 3)Big fire is not big enough or heating speed falls behind Firstly, check the pressure inside furnace: negtive pressure or possitive pressure, if it is negtive pressure, turn down the open degree of manual butterfly valve lightly to reduce the fume, adjust the adjusting screw on the mixer (outward rotation means reduce the LPG consumption, inward rotation means enlarge the LPG consumption). Please bear in mind that you should not adjust too fast, and should finish the regulation step by step and slowly. Or increase the open degree of manual ball valve and manual air butterfly valve to add the air and gas flow proportion to reach the increasing of combustion rate. 4)Charging mechanism does not work 20

22 The electrical eye fails to detect the billet (please adjust the detection distance to the proper place); the billet pusher didn't return to the final location; the buffer frame didn't move to the front limit, and the photoelectric switch of the billet feeding trough was covered by the dust or the hydraulic valve is tapped. 5)Main shear doesn t work Ejection back cylinder and ejection out cylinder didn t retreat to the limit, or the billet length was not set in the once cycle, the overflow vavel or hydraulic valve of the main shear is blocked. 6)Once cycle no action Without setting billet length; furnace door failed to open to the limited positon; the buffer board failed to retreat to the limited position, the billet turnover of feeding table didn t go down to the limited position, billet pushing forward limit is damaged. 7)Ejection back cylinder doesn t work Furnace door or the fixed shear didn t open to the limit; the main shear wasn t at the forward limit position or the blanking board wasn t at the up limit position. 8)Ejection out cylinder doesn t work Moveable shear didn t open to the limit; the main shear is not at the forward limit position, billet loader is not in the push limit position, the billet turnover device of the shear mouth is not in the drop limit position, the hydraulic valve is blocked. 9)Blower overload Please check the fastening and tightness of blower impeller and bearing. 10)Valve air leakage Please check the valve manually and operate the machine only after the problem has 21

23 been solved. 11)Breakdown alarm of overtop gas pressure Please check the outlet gas pressure of the reducing valve; if the valve is damaged please replace it, or please regulate the measure range of gas high pressure for electric contact. 12)Breakdown alarm of gas pressure is too low Please check gas flow supply; if the pressure is normal please check the filter. 13)Alarm of overtop furnace pressure Please check whether the electric actuator of smoke butterfly valve is operating, whether the furnace pressure transmitter is damaged or zero point draft appears. When the furnace is cold, please open the furnace door to achieve equal pressure inside and outside of furnace, and then adust the Z of the pressure transmitter to zero. If there are damaged please replace them; if all are normal, the alarm still exists, please check whether the fume pipe is blocked. 8. Electric schematic diagram 9. Combustion schematic diagram 10. Hydraulic schematic diagram 22

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