簡述

Introduction

輥型機是輪輞的專用加工設備，通常輥型加工包括3個工序（第1序，第2序和第3序成型），每一序需要1臺輥型機，每臺輥型機包括以下部分：輥型機主機、液壓系統、PLC控制系統、上下料機構和輥型模具。

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

設備規格

Specification

設備型號	Model Number	GX23/300-AH
輥型力	Roll Forming Force	230KN
液壓站電機功率	Motor Power of Hydraulic Station	82.5KW
主軸安裝模具長度	Spindle Length for Installing Molds	320mm
上下主軸轉速(可調)	Upper & Lower Spindle Speed range	0 ~ 320r/min
主軸材質和直徑	Spindle Material & Diameter	40CrMo, Φ145mm
上下主軸間距	Distance between Upper & Lower Spindle	240 mm ~ 380mm
下軸軸向可調范圍	Axial Adjusting Range of Lower Spindle	±2mm
下主軸行程(裝模處軸的直徑145mm)	Stroke of Lower Spindle: (axial diameter 145mm at die-setting)	140mm
下主軸接近速度	Loading Speed of lower Spindle	185mm/s
下主軸工進速度可調范圍	Feeding Speed’s Adjusting Range of Lower Spindle	2~10mm/s
下主軸可調傾角	Tilting Angle Adjusting Range of Lower Spindle	-0.34° to +0.17°
額定輸入電壓	Rated Input Voltage	380V/3phase
額定輸入容量	Rated Input Power	110Kw

輥型模具

Roll Forming Tool

輥型機上要安裝輥型模具，每個工序一套輥型模具。

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

機床調整特點

Machine’s Adjustment  

主軸的調整 /Main Spindle’S Adjustment

每個主軸都由擺臂支撐，擺臂采用鉸接與主軸相連，擺臂的鉸接點采用球軸承，后端的一個安裝在偏心機構上，通過偏心實現主軸的傾斜，為使兩主軸同步對稱相向調整，兩偏心機構用機械裝置耦合在一起，通過手輪進行調整，其作用為 ：

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)提供成型過程中所需的定型力，可以進一步控制產品質量。

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

2)補償主軸變形

Compensate main spindle’s transformation;

3)補償模具磨損

Compensate wear tooling

下主軸前后調節Forward & Backward Adjustment of Lower Spindle

下主軸水平前后調節機構，取代了原來加墊片的調整方法，更加便于調整模具。旋轉中軸螺栓（3）帶動鏈輪（2）轉動，鏈輪帶動齒套（4）旋轉，齒套（5）通過螺紋運動推動下主軸（2）移動，可以方便而又均勻的實現下主軸（2）上的型輥前后調整，取代了原來加墊片的調整方法，大大的提高了模具調整效率，降低了因調整片不合適，或長時間使用失效的問題。

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.

主軸轉速的調整 Adjustment of main spindle’s rotation speed

主軸采用液壓馬達驅動，液壓馬達安裝在成型機的后面，通過萬向節與主軸相連，上下液壓馬達分別驅動上軸與下軸向左右不同方向旋轉，調整液壓馬達回油口節流閥來改變上下軸轉速，使之上下輥模接觸工件時保持線速度的一致，防止劃傷工件與輥模。

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.

側導向的調整 Adjustment of side guide device

側導向用于保持輪輞在成型過程中的軸向位置，以及使輪輞中心處于模具中心之下，導向輪的位置可以根據工件狀況進行調整。

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.

側導向裝在上主軸兩側，每個側導向帶有滑道沿直線運動，為液壓驅動。

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.

側導向的啟始點和結束點通過手輪可調，每個側導向的上下均有接近開關作為控制單元。

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.

工件上下料裝置的調整Adjustment of loading/unloading device

上下料裝置高度的調整，根據工件直徑的大小來調整到合適的高度，可通過轉動升降的絲桿來完成。

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

工件推動到位的調整，可調整輥動料架前后的位置來完成。工件推到位后，輥動料架下部有鎖緊裝置，以穩定料架的位置，并有一行程開關接通發訊。

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.

拆卸型輥的推料裝置Push-ring for Dismounting Roll Forming Tool

在上下主軸（1）和（2）的根部都設計有推料環，通過油嘴注入干油，依靠油槍壓力推動推料環向前，從而推動主軸上的型輥向前有限的滑動，為順利拆卸型輥創造有利條件，便于快速拆裝型輥，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.