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Billet máquina de colada continua cizalla hidráulica mantenimiento y mantenimiento que no conoce
Fecha de lanzamiento:
2024-04-29
La cizalla hidráulica es un equipo muy importante en la producción de colada continua, la cizalla hidráulica es una forma de palanquilla de corte de máquina de colada continua, el uso de cizalla hidráulica afecta directamente la producción de la máquina de colada continua. La cizalla hidráulica es el equipo principal de la máquina de colada continua, debido a su contacto directo con la palanquilla de fundición a alta temperatura y en un mal entorno de trabajo. La alta temperatura hace que el cilindro hidráulico de cizalla hidráulica, la cuchilla y el límite sean fáciles de dañar, y el marco es fácil de deformar. Sin embargo, la vida útil de cualquier equipo no puede ser ilimitada, es probable que el equipo en el uso del tiempo tenga algunos problemas, por lo que la producción es difícil de continuar. Para extender la vida útil del equipo, mantener la producción y reducir los costos, hacer un buen trabajo en el mantenimiento diario y el mantenimiento de las cizallas hidráulicas, el mantenimiento es esencial.
Hydraulic shear is a very important equipment in continuous casting production, hydraulic shear is a way of continuous casting machine cutting billet, the use of hydraulic shear directly affects the production of continuous casting machine. Hydraulic shear is the main equipment of continuous casting machine, because of its direct contact with high temperature casting billet and in bad working environment. High temperature makes the hydraulic shear hydraulic cylinder, blade and limit easy to damage, and the frame is easy to deform. However, the life of any equipment can not be unlimited, equipment in the use of time is likely to have some problems, so that production is difficult to continue. In order to extend the service life of the equipment, maintain production and reduce costs, do a good job in the daily maintenance and maintenance of hydraulic shears, maintenance is essential.
1 composition of hydraulic shear
The hydraulic shear used by our company is a 45-degree suspended billet shear. The lower tool holder of the hydraulic shear is connected with the piston rod of the shear oil cylinder. The shear oil cylinder and the upper and lower tool holders are installed in a water-cooled integral square frame. The upper end of the frame has four wheels, all of which can run along the track. When the cast blank touches the fixed length signal, the transverse hydraulic cylinder pushes the frame to move forward synchronously with the cast blank along the horizontal track, while the lower shear blade moves upward under the push of the shear cylinder to cut the cast blank, and the cut cast blank is sent to the cooling bed by the transport roller. After the shearing is in place, the lower shearing blade begins to descend, and the resetting of the shearing machine is completed by the transverse hydraulic cylinder. This machine has the following characteristics:
1) Using 45 ° diagonal shear, the shear speed is fast (8 seconds to 15 seconds), and the shear section deformation changes little after the shear is completed.
2) In the entire hydraulic shear equipment body, a water-cooled tunnel is installed to improve the protection against cast blank radiation.
3) Grinding sliding bearings and wear-resistant rails use specially treated high-nickel-chromium materials, and their service life is 2 to 3 times that of traditional materials.
4) The hydraulic cylinder seal adopts a fully imported combined seal. The guide sleeve is a sintered porous bronze wire mesh on a steel plate, and the mesh is filled with a mixture of lead and polytetrafluoroethylene (PTFE for short).
5) compact structure, can be easily replaced as a whole, off-line maintenance, improve the operation rate and maintenance performance of hydraulic shear.
6) The equipment is assembled with bearing lubrication in the form of dry oil lubricating oil cup.
2 hydraulic shear maintenance and maintenance
Maintenance of 2.1 hydraulic shears
After each team takes over, all connections of hydraulic shears shall be inspected once. The pin shaft shall not be loose. If there is any looseness, stop pouring and tighten it in time. Check the hydraulic cylinder pressure and oil pipe for oil leakage. Check the service life of the hydraulic blade, check the use of the blade, whether there is a cutting edge off the phenomenon. The imported roller, water-cooled guard plate, metal hose and other water passing parts shall be inspected. If any leakage is found, stop pouring and timely treatment shall be carried out. Patrol inspection is the top priority of equipment maintenance work. Every patrol inspection must be carefully inspected, and early detection and early treatment must be used to eliminate equipment failures in the bud.
Maintenance of 2.2 hydraulic shears
2.2.1 Cooling and lubrication of hydraulic shears
Since the hydraulic shears must work continuously in harsh environments such as high temperature and heavy load in production, the parts of the hydraulic shears should be cooled and lubricated by water to prevent the hydraulic shears from being damaged due to excessive temperature or severe wear, and to extend the service life of the hydraulic shears.
The surface temperature of the cast billet in the hydraulic shear area is as high as 850 ℃, and the radiation will cause damage to the parts of the hydraulic shear. Hydraulic shear frame to adopt box structure for water cooling, hydraulic shear blade with external spray cooling. Lubrication of hydraulic shears is also essential. Good lubrication can extend the service life of equipment and reduce the labor intensity of workers.
2.2.2 Adjustment of hydraulic shear blade
The adjustment of billet shear is mainly to adjust the shear gap. First loosen the adjusting bolt of the backrest wear-resistant slide rail and the adjusting bolt of the lower support wear-resistant slide rail, so that there is a gap of 2-3mm between the slide rail and the wear-resistant sliding bearing, start the oil pump motor, press the "upward shear" button after the loading pressure reaches the set pressure, and release the "upward shear" button when the upper and lower blades are almost coincident, and stop the motor to adjust the shear gap. The shear gap refers to the sum of the gap between the upper and lower blades and the gap between the wear-resistant sliding bearing and the backrest wear-resistant slide rail. The shear gap is generally 1.0-1.2mm, and the upper and lower gaps are guaranteed to be consistent. Then fix the backrest wear-resistant slide rail, lock the adjusting bolt, and apply grease between the sliding bearing and the slide rail. The adjustment method of the gap between the lower wear-resistant sliding bearing and the wear-resistant slide rail is the same as the adjustment method of the shear gap.
2.2.3 Adjustment of hydraulic shear limit
Adjustment of the upper limit: The upper limit of the shearing machine is related to the service life of the shearing cylinder. The fixed position of the upper limit shall make the cylinder piston not top the cylinder head at the bottom of the cylinder, and it is advisable to overlap the movable blade and the fixed blade by 3-5mm.
2.3 equipment transformation
Hydraulic shear equipment prone to failure for the top blank, the main reason for the top blank may be the following:
1. The billet is not cut;
2. After the cutting is completed, the trolley does not return, and the cutting starts directly for the second time;
3. The main hydraulic cylinder limit fault, the main hydraulic cylinder is not back after shearing.
In view of the above problems, we have made several improvements:
1. Optimize the shearing procedure and confirm that the shearing time does not exceed 18 seconds, so that within a limited time, even if it is not cut for various reasons, there will be no top blank failure caused by the failure of the main cylinder rod not returning;
2. Add an alarm device for the trolley not returning (under the manual cutting function, the trolley needs to be returned manually. Due to the large flow rate and fast pulling speed of the continuous caster, the operator sometimes forgets to return or the trolley does not return due to the stuck valve of the reversing valve of the translation cylinder, which will directly cause secondary shearing to cause the top blank). If the trolley does not return, remind the operator in time to confirm the reason and avoid secondary top blank;
3. The hydraulic shear limit works in the environment of high temperature and water bath for a long time. Once the limit is affected by water, it is easy to fail. We will modify the one-sided wiring of the limit, and the opening position is downward to prevent water from entering and solve the fault caused by the limit problem.
In addition, in the mechanical aspect of the transformation of the car axle structure, to solve the insufficient strength of the shaft bending phenomenon; in terms of operation, an increase of semi-automatic shearing system, reducing the pouring when the manual operation of the process, fundamentally solve the problem of cumbersome operation.
2.4 Common Fault Analysis
2.4.1 Why does the shear cylinder not operate when the shear button is activated?
1) Check whether the pressure of the system pressure gauge is normal, whether the pressure of the accumulator is normal, whether the set value of the electric contact is normal, whether the translation pressure is normal, and whether the pressure holding state is normal.
2) Check whether the control circuit is normal (whether the shear relay indicator lights flash in sequence when normal).
3) Check whether the electromagnetic reversing valve is working (normally, the reversing valve indicator flashes and the coil is magnetic).
4) Check whether the main oil pipeline leaks.
5) Check whether there is foreign body stuck in the movable knife seat.
6) Check whether there is any foreign matter stuck in the solenoid reversing valve.
2.4.2 Why is the steel temperature above 800 degrees, but the shearing is very difficult or continuous?
1) Check whether the shear pressure of the system reaches more than 10MPa, and adjust the shear pressure of the system between 10-15MPa.
2) Check whether the electromagnetic relief valve is stuck. It can be judged by observing the shear pressure. It can be removed and cleaned.
3) Check the hydraulic pipeline for oil leakage.
4) Check whether the upper limit of the shearing machine is loose and slide down, so that the movable blade and the fixed blade cannot coincide.
5) Check whether the blade gap is too large, the normal gap is about 0.2-1mm.
6) Observe whether the upward shear time of the control panel is too short, normally between 10-15 seconds.
7) If the plunger pump is used for a long time, the flow and pressure of the oil pump will not be available, and the variable of the oil pump (small bolt at the top of the pump head) needs to be adjusted.
2.4.3 Why does the hydraulic shear body not automatically translate back to position after the shearing is completed?
1) Check the hydraulic shear track for foreign matter blocking the wheels.
2) Check the translation cylinder rod for strain, oil leakage or bending.
3) Check whether the pressure gauge corresponding to the translation cylinder has pressure indication.
4) Check whether the one-way solenoid valve and throttle valve corresponding to the translation cylinder work normally.
5) Check whether the pipeline is broken.
2.4.4 Why is the fault light on the console always red?
1) Check whether the upper and lower limit bit lines of the shearing machine are broken.
2) Check whether the billet is not cut, and the common end is not in contact with the upper limit.
3) check the upper and lower limit contact metal surface for foreign matter, scale and other foreign matter caused by poor contact.
2.4.5 Why do large oil cylinders sometimes leak oil
1) The oil cylinder expands and shrinks under high temperature baking, and the cylinder body becomes larger. Check whether the water cooling of the large oil cylinder is normal.
2) Check whether the sealing ring of the large cylinder is worn.
3) Check whether the backrest sliding bearing clearance of the lower knife seat is too large to cause cylinder holding, and adjust it appropriately.
2.4.6 Why does the shearing suddenly slow down, the oil pump is frequently loaded or always loaded, and the vibration of the oil pipe becomes larger
1) Check the air pressure of the accumulator. If the air pressure is too low (lower than 6MPa), nitrogen should be added to 6-8MPa.
2) Observe the pressure gauge of the system: whether the pressure disappears quickly after the accumulator is full. If so, check whether there is any foreign matter in the safety valve of the accumulator, so that the valve cannot be sealed, and the hydraulic oil returns to the oil tank directly through the oil return pipe.
3) Observe whether the accumulator is filled instantly, if so, check whether the accumulator has no air pressure or the bag is damaged
4) Check whether there is oil leakage in the pipeline
5) The contact in the electric contact pressure gauge is damaged and has poor contact. When the pressure reaches a high level, the main overflow valve cannot be closed, causing the motor to be loaded all the time.
6) The pressure given by the accumulator pressure holding overflow valve is lower than the high value of the electric contact. The pressure pointer of the electric contact cannot contact the pointer contact with the high value. The main overflow valve is always in working state and the motor is always loaded. (Only increase the pressure value of the accumulator pressure holding overflow valve until it is loaded on the pointer on the electric contact pressure gauge, or reduce the high set value of the electric contact pressure gauge)
3 Conclusion
Careful and timely maintenance can extend the service life of each part of the equipment, reduce the consumption of resources, reduce the cost, extend the service cycle of the equipment, reduce the number of maintenance, improve the efficiency, and bring more considerable economic benefits to the enterprise.
Palabras clave:
Mecanizado
Soldadura
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