简述

Introduction

辊型机是轮辋的专用加工设备，通常辊型加工包括3个工序（第1序，第2序和第3序成型），每一序需要1台辊型机，每台辊型机包括以下部分：辊型机主机、液压系统、PLC控制系统、上下料机构和辊型模具。

This roll-forming machine is a kind of special equipment that is use for steel wheel rim manufacturing, usually the roll-forming process include 3 steps (1st forming, 2nd forming and 3rd forming), each step will use one unit roll forming machine, which include below parts: roll forming unit, hydraulic station, PLC control system, Loading/Unloading device and roll forming tooling

设备规格

Specification

设备型号	Model Number	GX23/300-AH
辊型力	Roll Forming Force	230KN
液压站电机功率	Motor Power of Hydraulic Station	82.5KW
主轴安装模具长度	Spindle Length for Installing Molds	320mm
上下主轴转速(可调)	Upper & Lower Spindle Speed range	0 ~ 320r/min
主轴材质和直径	Spindle Material & Diameter	40CrMo, Φ145mm
上下主轴间距	Distance between Upper & Lower Spindle	240 mm ~ 380mm
下轴轴向可调范围	Axial Adjusting Range of Lower Spindle	±2mm
下主轴行程(装模处轴的直径145mm)	Stroke of Lower Spindle: (axial diameter 145mm at die-setting)	140mm
下主轴接近速度	Loading Speed of lower Spindle	185mm/s
下主轴工进速度可调范围	Feeding Speed’s Adjusting Range of Lower Spindle	2~10mm/s
下主轴可调倾角	Tilting Angle Adjusting Range of Lower Spindle	-0.34° to +0.17°
额定输入电压	Rated Input Voltage	380V/3phase
额定输入容量	Rated Input Power	110Kw

辊型模具

Roll Forming Tool

辊型机上要安装辊型模具，每个工序一套辊型模具。

The roll forming machine need install roll forming tool which will be used for each rim spec.

机床调整特点

Machine’s Adjustment  

主轴的调整 /Main Spindle’S Adjustment

每个主轴都由摆臂支撑，摆臂采用铰接与主轴相连，摆臂的铰接点采用球轴承，后端的一个安装在偏心机构上，通过偏心实现主轴的倾斜，为使两主轴同步对称相向调整，两偏心机构用机械装置耦合在一起，通过手轮进行调整，其作用为 ：

Every main spindle is hold by pendular arms, which connects with main spindle by hinge. The hinge point of pendular arm adopts ball bearing. The back one is installed on an off-centre device. The main spindle inclined is realized through eccentric. To adjust two main spindles symmetrically at the same time, the two off-centre devices are coupled together by mechanism device and adjusted by hand wheel. Its main function is following:

1)提供成型过程中所需的定型力，可以进一步控制产品质量。

Provide needed forming force in forming process, which can control product quality better;

2)补偿主轴变形

Compensate main spindle’s transformation;

3)补偿模具磨损

Compensate wear tooling

下主轴前后调节Forward & Backward Adjustment of Lower Spindle

下主轴水平前后调节机构，取代了原来加垫片的调整方法，更加便于调整模具。旋转中轴螺栓（3）带动链轮（2）转动，链轮带动齿套（4）旋转，齿套（5）通过螺纹运动推动下主轴（2）移动，可以方便而又均匀的实现下主轴（2）上的型辊前后调整，取代了原来加垫片的调整方法，大大的提高了模具调整效率，降低了因调整片不合适，或长时间使用失效的问题。

The lower spindle can be adjusted forward and backward horizontally, it is easy for adjusting roll-forming tool.

Attached below drawing to show operating principle, its adjustment process is:

Turning the bolt 3 of middle axle to drive the chain wheel 2 -> and chain wheel drive gear sleeve 4 and gear sleeve 5 -> to power the lower spindle 2 moving by screw thread -> for achieving forward and backward adjustment of forming roller which mounted with lower spindle 2.

主轴转速的调整 Adjustment of main spindle’s rotation speed

主轴采用液压马达驱动，液压马达安装在成型机的后面，通过万向节与主轴相连，上下液压马达分别驱动上轴与下轴向左右不同方向旋转，调整液压马达回油口节流阀来改变上下轴转速，使之上下辊模接触工件时保持线速度的一致，防止划伤工件与辊模。

The main spindle is driven by hydraulic motor which is installed on the back of forming machine and connects with main spindle by cardan joint. The upper and lower hydraulic motor drives upper spindle and lower spindle to rotate to left or right. Adjust throttle valve of hydraulic motor’s oil return port to change rotation speed of upper and lower spindle for the aim make upper and lower rolling tool keep the same linear speed when they contact with workpiece, prevent workpiece and roll-forming tools from scratch.

侧导向的调整 Adjustment of side guide device

侧导向用于保持轮辋在成型过程中的轴向位置，以及使轮辋中心处于模具中心之下，导向轮的位置可以根据工件状况进行调整。

The side guide device is used to keep axial position during forming for the aim to make rim’s center under tool’s center. Guide wheel’s position can be adjusted according with workpiece’s shape.

侧导向装在上主轴两侧，每个侧导向带有滑道沿直线运动，为液压驱动。

The side guide device is installed on two sides of main spindle. Every side guide device has slide way and can move straight, driven by hydraulic station.

侧导向的启始点和结束点通过手轮可调，每个侧导向的上下均有接近开关作为控制单元。

The start point and end point of side guide can be adjusted by hand wheel. Every side guide has proximity switch on top and bottom as control unit.

工件上下料装置的调整Adjustment of loading/unloading device

上下料装置高度的调整，根据工件直径的大小来调整到合适的高度，可通过转动升降的丝杆来完成。

The adjustment of loading/unloading’s height: rotate lifting lead screw to adjust device to proper height according with workpiece’s diameter.

工件推动到位的调整，可调整辊动料架前后的位置来完成。工件推到位后，辊动料架下部有锁紧装置，以稳定料架的位置，并有一行程开关接通发讯。

Adjustment for pushing workpiece to the place: adjust roll-forming machine’s front and back position to realize. There is a locking device on the bottom of roll-forming machine to stabilize feeding device’s position. It also has a stroke switch to transmit signal.

拆卸型辊的推料装置Push-ring for Dismounting Roll Forming Tool

在上下主轴（1）和（2）的根部都设计有推料环，通过油嘴注入干油，依靠油枪压力推动推料环向前，从而推动主轴上的型辊向前有限的滑动，为顺利拆卸型辊创造有利条件，便于快速拆装型辊，提高了效率。

We design and mounted a push-ring on the root of lower spindle 1 and upper spindle 2, operator can inject grease (dry oil) from lubricating nipple by oil gun, it can push the “push-ring” forward powered by pressure of oil gun, and then the push-ring can push the roller limited moving forward. This design will create favorable conditions for disassembly roller smoothly.