Disc Shears Explained, Rolling Technology (51)
1. Process principle
Function: Use two pairs of rotating blades to cut off the edge of the steel strip to determine the predetermined width of the strip.
Trimming width: ≥5mm (each side), ≤40mm (each side);
Trimming speed: exit line speed;
Gap Adjustment Device: The mechanism includes a preloaded fine adjustment screw positioned by a double thrust bearing.
Range: 0.04～0.6mm;
Accuracy: ± 5µm;
Overlap adjustment: Adjusted by a special stepper motor mounted on the end of the fine adjustment screw.
Range: +2～-1.6mm;
Accuracy: ±0.01mm;
Angular head opening adjustment device: ensure the precise adjustment of the parallelism of the two cutting surfaces, so that a small opening can be easily adjusted to facilitate cutting and reduce tool wear. Two lead screws can adjust the range of the head ± 1°.
blade:
Use time: about 120km between two replacements;
Grinding amount per time: 0.3 to 0.5mm;
Blade life: about 20 times of grinding;
2. Working status
1. The rotating blade of the disc shear can be replaced without stopping the line. There is a special equipment for the shearing blade that allows the mechanical clearance of the shearing blade to be adjusted when cutting thin strips.
2. Two electric systems allow the side cutting edge to independently adjust the gap in the horizontal and vertical directions of the trimming. Changing the blades of the disc shears is simple and takes about 1 minute (operator on both sides). Easy removal/replacement of the blade is possible by hydraulic nut, also using the scrap sheared on both sides of the drive bearing directly into the scrap bin.
3. Details
(1) Two rotating disc shearing blades
(2) Deburring machine at the end of the rotary disc shear (standard arrangement)
(3) Deburring machine located at the end of the rotary disc shear
There is a compact arrangement on the shell of the disc scissors, the distance is short, so there is a safety guide device between the disc scissors cutting edge and the waste box. The movable, rotating mobile knife holder can ensure the continuous operation of the cutting edge, equipment adjustment and locking Keep the blade in and out, and the center of the blade on the longitudinal auxiliary facility, so that more real waste can flow out. If there is no stacking amount, a carbide blade should be used at the entrance, and the service life of the material will be longer. The deburring machine is preloaded for the lower cutting edge without clearance, and the locking of the housing and movement of the cutting edge is done by a hydraulic piston.
The installation of the tapered ball screw is adjusted to the head of the wide knife. The ball screw spindle gets installed with an overload slip clutch. A remote control trimming compartment can be obtained with the installation of an electronic highly accurate adjustment encoder for position. The guide tracks as well as the drive and adjustment spindles are fully covered with telescopic covers, thus ensuring low wear and long possible maintenance intervals by manual lubrication of the sliding surfaces with a layer of grease on the transport. All lubricated shafts and roller bearings are simple and easy to operate, using hydraulic clamping nuts to change the calibrated blade clearance of the blade, the depth of penetration of the blade in our workshop. Since all widths of modules that support pass-through knives can be installed, there is no re-calibration (knife-edge clearance is always unchanged). None of the blade diameters have been reground and there is no need to recalibrate the penetration depth. Manufacture of cutting tools that support strip steel in front of backing rolls 2 Cantilever cranes 2 Assembly equipment Assembly and installation of rotary cutter heads for disc shears including: The lathe of the disc shears is a bending-resistant and oil-sealed welded structure with 2 conveying rails.
In addition, the width adjustment of the spindle bearing ball is an integral part of this shearing lathe. On the top, the shearing lathe is fully protected by two telescopic covers. Two mobile trolleys provide drive and width setting devices, and the guidance of the lathe movement is completed by nylon sliding pads and fixed position reaction forces. The movement of the clamp for the shearing position is completed by the hydraulic piston installed next to the running trolley, and the spherical turntable on the two rotary tables is a stable welded structure. The table is rotated by a hydraulic motor, and the working position is locked by a hydraulic piston. The four shear housings are designed to connect with the cutter shafts at the top and bottom of their respective box supports when not in operation. The cutter shaft bearings include pre-stressed bearings seat.
Cutting edge clearance - and cutting edge penetration are adjusted at the top of the cutter shaft (harmonic gearing) Recording of setting values ??using an absolute position indicator by adjusting the cutting edge penetration depth The front cutter shaft bearing seat is controlled by the wedge plate hydraulic tool in its position mechanical response.
Four burr smoothing devices are attached with shear tolerances 8 shearing edges in total in 2 sets of shear combinations, as well as support rings and hydraulic adjustment nuts Three of the four discarded mandrels are screwed in shear by wear-resistant material on the shell. The scrap is easy to remove, and the cover opens to a certain extent on its guide plate, which can be lifted horizontally and controlled by the limit switch, and the cover is quickly lifted by the scrap when the line is stopped.
Width adjustment Drive control is controlled by servo-driven safety coupling and safety cover The size control of the cutting edge of the disc shear is carried out by an electronic encoder, a universal joint flange shaft The motor power is transmitted to the reverse drive of the motor two Lead ingots with high thread precision are synchronized with each other with a universal joint shaft.
Three Disc Scissors Adjustment
The 2-knife heads on the transmission side and the operating side are connected and movable/separated by two identical partial encoders and 2-knife transmission side heads. Determined by the width of this sport trim.
Both parts are equipped with a set of double-sided fine-tuning rotatable dials. Arranging tool change changes enables turning the rotary table and turning using another set of accessories. The position of a new knife can be restarted, and the old knife can be changed during production.
During production, a pair of knives is used as a spare. At the same time; - the old knives on both sides will be opened soon; - the shearing rotary table will be forward/separated position; - the working position of a pair of new knives on both sides, will be the standby position, turn the table; (For new knives, Gap and Overlap settings show completed preset table) - Cut house will be back/preset width position; - Side trim will restart;
1. Strip width adjustment
The two-knife section of the knife can be traversed together/separated by the head as needed by controlling the AC motor.
2. The change of strip width, the following applies to the transfer of the cutter head
If the previous strip is as wide as 800mm and the new strip is as wide as 1200mm (ie strip width varies from narrow to wide), the new reference can be in direct contact with the drive motor operating at creep speed. However, if the width of the strip varies from wide to narrow, the new reference value must first be accessible to operate the drive motor at creep speed.
3. It is necessary for the heads of these cutters to be shifted in a cycle in order to compensate for shaft tolerances and to achieve the width adjustment required for high precision.
Correction factors must be foreseen to compensate for differences in distance between machines. The knife change width adjustment separates the wires until the proximity switch *01 SBE is active. After the new knife is turned around, the width adjustment positions traverse together to the new preset width. The pattern doesn't have a side swivel to adjust the width to traverse distinct positions.
Definition of direction: - forward gap increase (+); - backward gap decrease (until "zero"); - forward means knife opening direction: overlap decrease (-) / quick open; - backward means Knife Closing Direction: Overlap Increase (+);
3. Common problems
In the actual production process, there are often problems such as the edge wire not falling off, the groove marks left on the edge of the strip, the uneven cut surface, and the width of the strip. Through years of production practice, some effective methods have been summarized.
(1) The disc shear does not need the motor to drive the movement, and the strip drives the movement, so there will be burrs on the edge of the strip. Deburring rollers can do the trick.
(2) The middle pressure rollers of the scissors on both sides must press the strip steel to prevent the strip steel from bulging during the trimming process, causing the strip steel to be wide after trimming.
(3) When the blade is curved, its circumferential gap is not equal, which will cause uneven trimming of the strip, which can be eliminated by grinding the plane of the scissors.
(4) There is a pressure wheel close to the scissors at the shaft end of the fixed scissors. If the difference between the diameter of the scissors and the diameter of the scissors is less than the thickness of the strip to be cut, the lower surface of the strip will be pressed with a uniform strip groove equal to the thickness of the lower scissors.
(5) If there are burrs in the cutting edge, the burrs are easy to squeeze into the gap between the scissors and the pressure roller, and accumulate on the scissors, which will cause a certain depth of groove marks on the cross section of the strip. It can be solved by replacing the blade.
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