The Ultimate W24S Hydraulic Profile Bending Machine Manual

1. Hydraulic profile bending machine Usage

The W24S series rolling machine is a hydraulic three-roller profile bending machine that is mainly used for bending various steel profiles. It is capable of rolling “O” spiral-shaped workpieces and is widely used in industries such as petroleum, chemicals, shipbuilding, metalworking, and machine manufacturing.

2. Main Technical Data

Here are the drawings:

Technical Specifications

Model and specification

Please select the appropriate model based on the maximum bending resistance modulus of the profiles.

3. The main structure and working principle of hydraulic profile bending machine

The W24S profile bending machine comprises of a machine body, side roller section, support roller section, electrical system, and hydraulic system. The machine body is constructed as a single, welded unit and features two running arms, which are driven by two hydraulic pumps and perform an upward and downward arc movement.

Additionally, support rollers are situated on both ends of the machine body and can be adjusted to various angles to accommodate various profile bending needs.

4. Drive system

The primary drive system is composed of a motor that drives a reducer, which then transmits power to the side rollers and finally to the upper roller.

5. Function, working process and working field

  • Machine function

The three main rollers are driven and perform the pre-bending operation. By adjusting the guide rollers, it is possible to rectify any deformities that may occur during the bending process.

  • Working process

The machine is capable of performing pre-bending, and the process is as follows:

Working process of hydraulic profile bending machine
  • Working field

The main parameters indicated in the form represent the maximum bending capacity and optimal working efficiency. If the steel profile is in the form of a square or angle and has a bending resistance modulus less than 45 cm3, it can be bent successfully on the W24S-45.

  • Bending way
Bending way of hydraulic profile bending machine

6. Hydraulic system

The hydraulic system is equipped with an electromagnetic pressure relief valve. The roller cylinder rises and falls through two solenoid valves on both sides of the roller cylinder, and the electromagnetic relief valve must be powered for the system to build pressure.

When the solenoid valve YV01 and YV2 receive electricity, the left tank rolls up, and when YV01 and YV2 receive electricity, the left tank rolls down, while the right roll operates similarly. The working fluid for the system is 30-40# ordinary hydraulic oil.

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It is important to check the motor rotation before testing to ensure it is correct and to monitor the fluid level in the secondary fuel tank. The oil should be checked every six months for signs of deterioration or replaced with new oil if necessary, and the oil temperature should not exceed 70°C.

7. Electrical system

  • W24S-45 uses 380V/50HZ/3PH electricity.

8.Installation and commissioning of hydraulic profile bending machine

8.1 Installing

The machine is packaged as a complete unit in a steel carton. Upon arrival at the client’s location, it is important to verify that the contents of the packing list match the actual machine. Before conducting any debugging, oil must be added to the machine.

8.2 Debugging

8.2.1 Preparation before Debugging

Please check all connections and clamping parts to ensure they are secure.

Please check the hydraulic oil level and ensure that the lubrication is sufficient.

Please check the voltage of the electricity supply.

8.2.2 Running without Loading

After completing the checks outlined above, please run the main drive and perform up and down movements for a cycle of 15 minutes.

Check and adjust the up rollers and side rollers to ensure that the distance is suitable and the machine can operate effectively.

8.2.3 Test Requirements

Movements should be smooth on both sides of the roll.

The roller rotation and lift should be flexible and operate smoothly.

All transmission parts should not produce any abnormal noises.

All fasteners should be securely tightened and the machine should be well-oiled.

The bearing temperature should not exceed 35°C, with the highest temperature not exceeding 70°C. The temperature of the hydraulic pump oil should not exceed 60°C.

8.2.4 Load Test

A load test should only be performed after a successful no-load test. The general procedure is as follows:

Set the basic parameters according to the relevant profile parameters specified in the table. Pre-bend the sections of the treated end.

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Score the operational proficiency by sub-volumes into the diameter of round workpieces as specified in the provisions.

8.2.5 Load Test Requirements

The load test should meet the basic performance requirements specified in the relevant parameters.

During the load test and load operation process, the transmission system should be stable and produce no abnormal noises. The operating system should be flexible, accurate, and reliable. The bearing temperature must not exceed the previously mentioned limits.

There should be no slipping between the rolling die and the profiles during the process.

9. Operation rules and safety maintenance of hydraulic profile bending machine

9.1 Preparation and inspection before use

Before using the aircraft, please read this note to gain an understanding of its technical performance and operating methods. It is imperative to strictly follow the safe operating procedures outlined in the system and to prepare for work in accordance with the requirements outlined in Article 8.2.1. This includes removing the oxide from the rolled profiles, grinding the edges, and removing the weld.

9.2 Safety and Protection

When using the machine, please pay close attention to the following safety concerns:

Overloading the machine is strictly prohibited.

During use, if any irregular noises or impacts are detected, the machine should be immediately stopped for inspection.

The transmission mechanism and joints should be regularly checked during use to ensure that they are secure and free of damage.

9.3 Operation way

The height of the profiles will be reduced on both sides of the roll according to the specified dimensions.

The profiles will be processed and passed through the rollers on both sides.

The round workpieces will be processed until they meet the required specifications.

After the main drive has been stopped, the edge roller should be lowered and the workpiece can be removed.

Effective lubrication of the machine is an important measure to reduce power consumption and increase its lifespan. To achieve this, it is necessary to choose the right lubricants and establish a proper lubrication system.

9.4.1 Lubrication The machine uses lubricating oils for lubrication, which can be done through artificial refueling, oil cups, or a lubricating oil tank.

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9.4.2 Lubricant Selection For artificial refueling, calcium-based grease should be used. For oil cup lubrication points, calcium-based #2 grease should be used in the summer and calcium-based # grease should be used in the winter.

9.4.3 Lubrication System and Notes The user should establish a specific lubrication system based on the specific circumstances of the machine, load, and operation.

Before starting the machine, all lubrication points must have a sufficient oil supply.

In continuous operation, the oil in the oil cups should be replenished in general 4 hours, and the gears should be lubricated once a month in general. The entire lubrication system should be cleaned once a year.

10. The lifting of machine tool & maintenance

Proper use, reasonable maintenance, and repair can not only extend the life of the machine, but also reduce repair costs. The following are the main points of maintenance and repair for the aircraft:

10.1 The machine must be in good working condition and well-oiled before use. The lubrication system should be strictly followed.

10.2 During the rolling of profiles, the oxidation between the skin and die should be promptly removed.

10.3 Worn parts should be promptly replaced, and parts that no longer meet performance requirements should be replaced.

10.4 The electrical system should be regularly maintained, dust should be cleaned, and failed components should be replaced in a timely manner.

10.5 During operation, the temperature of moving parts should be monitored to ensure it does not exceed the prescribed limits.

11. Hydraulic schematic diagram

Here are the drawings:

Hydraulic Diagram

12. Electrical apparatus principles graphics

Here are the drawings:

Electrical Diagram 1

Electrical Diagram 2

Electrical Diagram 3

Electrical Diagram 4

Electrical Diagram 5

Electrical Diagram 6

Electrical Diagram 7

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