PUL35/3 CNC Punching Machine for Flanges of U-Beam Used for Lorry Beams Model

Product Description

Production Description:
    PUL35/3 CNC Truck Longitudinal Three-side Automatic Hydraulic Piercing Machine 

    Machine Purpose:
    This production line can be used for three-dimensional NC punching machining of the longitudinal beam with equal cross section of the automobile.

    The production line has the characteristics of high processing precision, fast punching speed and high production efficiency.

    The whole process is fully automatic and flexible, which can adapt to the mass production of longitudinal beam, and can be used to develop new products with small batch and many kinds of production.

    The production preparation time is short, which can greatly improve the product quality and production efficiency of the automobile frame.

Machine Features:

1,Loading and unloading trolley .

    It is used to carry the U-shaped longitudinal beam and send it into or out of the production line. The U-shaped beam is placed on the material trough. The U-beams on each floor are separated by partitions to prevent the U-beams from skewing. The material trough with U-shaped longitudinal beam is hoisted to the conveying vehicle by crane, and then the conveying vehicle moves to the position where the material can be fed by the magnetic suction cup of the magnetic feeding device for feeding.
 2,Magnetic feeding device 
    The U-shaped longitudinal beam is sucked from the feeding conveying trolley to the longitudinal material path. The magnetic chuck adopts the electric permanent magnetic chuck, which is full of magnetism in normal state. When the magnetic chuck is powered on, the magnetic force of the magnetic chuck disappears. The magnetic chuck assembly is equipped with a probe to detect whether there is material during the feeding lifting, which can timely determine the opening direction of the longitudinal beam and whether the longitudinal beam is lifted. When the longitudinal beam is lifted to a certain height by the magnetic suction cup, the front and back moving trolley in the horizontal direction will send the longitudinal beam to the feeding channel smoothly. The motor is driven by the rack and pinion to make the longitudinal beam move smoothly and accurately. The magnetic feeding device can automatically select the position of the longitudinal beam for feeding without moving the feeding trolley.
3,Feed channel
    It is used for feeding U-shaped longitudinal beam. It is composed of fixed supporting roller, rotating supporting roller and feeding driving roller. Each group of fixed support raceway components is composed of fixed seat, fixed support roller, mobile support roller and cylinder, side positioning roller, side pushing roller and side pushing cylinder. The mobile support roller is driven by cylinder to adapt to different width longitudinal beam.Each group of rotary support raceway components is composed of fixed seat, mobile support roll, side positioning roll, swing cylinder, side push roller and side push cylinder. The moving support roller is driven by the air cylinder to move downward to adapt to the longitudinal beams with different widths; The side positioning roller within the travel range of the clamp is driven by the swing cylinder to rotate and stand up to let the hydraulic clamp pass.
   
     Each group of rotary support raceway components is composed of fixed seat, mobile support roll, side positioning roll, swing cylinder, side push roller and side push cylinder. The moving support roller is driven by the air cylinder to move downward to adapt to the longitudinal beams with different widths; The side positioning roller within the travel range of the clamp is driven by the swing cylinder to rotate and stand up to let the hydraulic clamp pass.
     When the magnetic feeding device transports the U-shaped beam to the support roll of the feeding channel, the side pushing cylinder drives the side pushing roller to push the U-shaped beam against the side positioning roll, and the feeding driving roll transports the U-shaped beam to a fixed position (there is a detection switch here) for clamping the longitudinal beam by the hydraulic clamp of the clamping device.

4,Feeding manipulator                             

    The function of the feeding manipulator is to clamp the longitudinal beam and feed it along the x-axis direction. After the feeding manipulator sends the longitudinal beam out of the web numerical control punching machine, the middle manipulator continues to clamp the longitudinal beam and feed it.
 

5,Movable web CNC punching machine

   
    It can move along x-axis and y-axis, each driven by a servo motor. It can punch the web of longitudinal beam together with the small web plate CNC punching machine. The die bracket adopts a linear structure, and the dies are distributed in a straight line. The cushion block is pushed by the air cylinder, and different dies are selected to participate in stamping, so that the die can be changed quickly. The hydraulic pressing punching process is adopted. Before punching, the longitudinal beam is leveled and tightened by the pressing plate, and then the punching is completed by the punch. When the punch returns, it is forced to withdraw the punch completely from the longitudinal beam, and then the pressing plate is lifted up and reset. The die has long service life and high safety. The punching datum can be left or right of the longitudinal beam width direction. Since the dimension and straightness of the longitudinal beam have tolerance, the longitudinal beam must be inspected during punching. The detecting element is a displacement sensor, which is connected with a roller, and the roller is pushed by the air cylinder to measure against the longitudinal beam flange. When the longitudinal beam stops moving and is ready to punch, the displacement sensor detects the y-direction position of the longitudinal beam abdomen and corrects the actual position and size of the hole. Several displacement sensors are set on both sides of the longitudinal beam for detection. When punching, it is detected by the displacement sensor nearest to the punching position. When the laser line is cut off at the end of the workpiece, the counting module is cleared and used as the zero coordinate of the X axis, and then the punching process begins
 

6,CNC punching machine for large web plate 

        It can move along the Y-axis and is driven by a servo motor to punch the web of the longitudinal beam. It can move along the Y-axis and is driven by a servo motor to punch the web of the longitudinal beam. Hydraulic pressing punching process is adopted. Before punching, the longitudinal beam is pressed by the pressing plate, and then the punching is completed by the punch. When the punch returns, the punch is forced to withdraw completely from the longitudinal beam, and then the pressing plate is lifted up and reset. The die has long service life and high safety. The punching datum can be left or right of the longitudinal beam width direction. Since the dimension and straightness of the longitudinal beam have tolerance, the longitudinal beam must be inspected during punching. The detecting element is a displacement sensor, which is connected with a roller, and the roller is pushed by the air cylinder to measure against the longitudinal beam flange. When the longitudinal beam stops moving and is ready to punch, the displacement sensor detects the y-direction position of the longitudinal beam abdomen and corrects the actual position and size of the hole. Several displacement sensors are set on both sides of the longitudinal beam for detection. When punching, it is detected by a displacement sensor nearest to the punching position.

Intermediate manipulator

Connect the longitudinal beam after the feeding manipulator is sent out of the web numerical control punching machine, and continue to feed the longitudinal beam along the x-axis direction
 

7,Intermediate manipulator
 

    Connect the longitudinal beam after the feeding manipulator is sent out of the web numerical control punching machine, and continue to feed the longitudinal beam along the x-axis direction

8,Fixed wing CNC punching machine
 

    The die bracket adopts a linear structure, and the die is distributed in a straight line. The cushion block is pushed by the air cylinder to select different dies to participate in stamping. The workpiece is fed along the x-axis direction, and the punching machine moves along the z-axis. Then the punch with different diameters is replaced in turn through the die changing system to complete the processing of the holes on the longitudinal beam flange.  

9,Movable flange CNC punching machine

    The working principle of the movable wing numerical control punching machine is the same as that of the fixed wing numerical control punching machine. The movable flange CNC punching machine can move in the y-axis direction to adapt to the longitudinal beam width 
                 

10,Discharge manipulator

    The middle manipulator is sent out and connected with the longitudinal beam of two wing plate CNC punching machines, and the middle manipulator is sent in along the x-axis direction. After all the holes on the longitudinal beam are processed, the longitudinal beam is driven away from the numerical control punching machine of the wing plate. The hydraulic clamp of discharging manipulator can float up and down, front and back. The discharging manipulator sends the processed U-beam to the discharging channel for the magnetic blanking device to place the longitudinal beam on the blanking trolley.           
                  

11,Discharge channel  
 

    The fixed support raceway is composed of fixed seat, fixed support roll, mobile support roll and air cylinder. The mobile support roll is driven by air cylinder to adapt to different width of longitudinal beam.
    The rotary support raceway component on the clamping and discharging device is composed of a fixed seat, a rotary support roller, a swing cylinder, etc. The rotary support roll is driven by the swing cylinder to rotate and lie down, so as to adapt to the longitudinal beam of different width and let the hydraulic clamp pass through.           
                      

12,Automatic chip conveyor
 

    It is composed of magnetic chip remover and scrap car. The waste falling from each punching machine is transported to the chip conveyor, and then carried into the waste trolley by the chip conveyor. It is equipped with two waste trolleys for alternate use.                 
           

13,Hydraulic system
 

    The production line adopts the hydraulic system specially designed by H + L company of Germany for automobile beam punching production line. The hydraulic system adopts electro-hydraulic and mechanical common servo to control the upper and lower dead points and the middle position, which is more reliable and accurate than the single electro-hydraulic servo valve.
The hydraulic system combined with digital card controller HS2 for automobile beam sheet stamping can monitor the whole punching process and accurately control the middle position of punch to stop.           
                   

14,Pneumatic system
 

    It is mainly used for mold selection, pressing plate lifting, longitudinal beam positioning and guiding, supporting roll movement, driving roll clamping and driving, etc. The compressed air is required to be free of dust and water.                     
          

15,lubrication system
 

     The lubrication system adopts the combination of centralized lubrication and decentralized lubrication. 

16,electrical system 

    The hardware of the electrical control system consists of a complete set of Siemens 840D SL numerical control system, frequency converter, touch screen, detection and protection components, etc.

17,System function overview:

• Optimized all digital solution, integrated motion control function, make the stamping equipment faster, more accurate, more smooth operation.
• Lead screw pitch error compensation and measurement system error compensation; Reverse clearance compensation.
• Various limit protection functions.
• Power loss memory function ensures the stability of system data.
• The integrated acceleration feedforward control function can eliminate the contour error caused by the following error and improve the precision of high-speed stamping.
• The optimized drive parameters and system data are stored in the flash memory card, and the module is replaced without further optimization.
• Characteristics and working mode of electrical control system:
• Modular design is adopted.
• All parts of the system are connected by bus communication.
• The user program is loaded by USB flash disk or transmitted by network interface, so the reliability is enhanced.
• The display part shows various operation pages of each component, which is convenient and reliable for operation and timely for fault diagnosis.
• There are two working modes: manual mode and automatic mode: In the manual mode, the operator controls the action of each unit by inching through the buttons on the control panel.; In the automatic mode, all kinds of classification actions can be completed automatically without operator intervention, but according to the pre programmed processing program.
• Description of several main components of electrical control system:
• Siemens CNC system:
• It runs in the control mode, programming mode and operation interface mode of standard CNC machine tool.
• Complete the motion control, I / O control, detection function, communication function, diagnosis and alarm function of the whole equipment.
• Windows operating system is installed in the CNC system
• 12 inch color display
• Driving part (including AC servo motor)
• The system is controlled by Siemens digital AC servo and has high acceleration and deceleration performance.
• Frequency converter:
• The frequency converter has powerful function and thousands of control parameters.
• In the process of operation, it can be switched between different process parameters, and the control is flexible and convenient.
• The operation speed of the magnetic loading and unloading device is controlled, and the feeding positioning is accurate and stable.
• Automatic programming software function:
• Automatic calculation of tool offset;
• Automatically filter out the overlapped holes;
• It is suggested that the hole in the dead zone, the interference hole and the notch hole at the edge;
• Mold warehouse management;
• Mold matching function: automatically match the mold according to the given mold deviation, lack of mold alarm;
• Optimize the processing process and improve the processing efficiency;
• Automatic section feeding: solve the relay transmission of multi clamp feeding, without manual calculation;
• Define dead zone: automatically check the processing dead zone of each die (at the fillet) and mark the holes that cannot be processed;
• It can accept the drawing files in DWG. DXF format;
• It can run on Windows XP, Windows 7 and windows 10;
• The electric cabinet is equipped with air conditioning device to ensure the stable and reliable operation of the numerical control system and the appropriate working temperature. It has a 220 V socket for maintenance and good lighting.
• With reliable leakage protection device, it has complete line protection function; The cable trough box is used for the wiring between the equipment to ensure the safe and beautiful wiring.

Main Technical specification

Data of longitudinal beam before machining	Data of longitudinal beam before machining	σb=510-890     MPa
	Length of longitudinal beam	4000~12000 mm  (+5mm)
	Inside width of longitudinal beam web	150-340 mm      (+2mm)
	Stringer flange height	60-110 mm       (±5mm)
	Longitudinal beam thickness	4-10 mm
	Fillet radius	R10 mm         (+2mm)
	Longitudinal straightness deviation of Web	0.1%, ≤10mm/ overall length
	Longitudinal flatness deviation of airfoil	0.5mm/m, ≤6mm/ overall length
	Maximum twist	5mm/ overall length
	Angle between wing and abdomen	90^o±1
Data of longitudinal beam after machining	Punching diameter of Web	maximum Φ 65. Minimum plate thickness
	Punching diameter of wing plate	The punching diameter of wing plate is the largest Φ 23. Minimum plate thickness
	The minimum distance between the center of the ventral most hole and the inner surface of the airfoil	Aperture ≤ Φ 13  20mm Aperture ≤ Φ 23  25mm Aperture > Φ 23  50mm
	The minimum distance between the inner side of longitudinal beam ventral surface and the center of flange hole is	25  mm
	The punching accuracy shall be controlled within the following range (except for the range of 200 mm at both ends) and the center distance accuracy between holes	Tolerance value of hole spacing in X direction: ± 0.3mm/2000mm; ±0.5mm/12000mm Tolerance value of group hole distance in Y direction:±0.3mm
	Hole margin	±0.5mm
Die position and stamping stroke of main machine	Mobile web CNC punching machine	18 modules, straight line.
	CNC punching machine for large web plate	21 modules, straight line  ,5 modules ofΦ25.
	Fixed wing CNC punching machine	6 modules, straight line.
	Movable flange CNC punching machine	18 modules, straight line.
	Stamping stroke of main engine	25mm
Line pitch		When the length of the uniform section longitudinal beam is 12 meters and there are about 300 holes, the punching time is about 7 minutes / piece
line leader		about 36000mm *8500mm*  4000mm.
Loading and unloading trolley	Conveying stroke	about 2000mm
	Conveying speed	about 4m/min
	Stacking height	about 500mm
Magnetic feeding device	Horizontal travel	about 2000mm
	Horizontal motor power	1.5kW
	Vertical travel	about 600mm
	Vertical motor power	4kW
	Number of electromagnets	10
	Electromagnet suction	2kN/each
Feeding manipulator	Maximum speed	40m/min
	X-axis stroke	about 3500mm
Numerical control punching machine for movable web plate	Nominal force	800kN
	Punch type	9
	Module number	18
	X-axis stroke	about 400mm
	X-axis maximum speed	30m/min
	Y- axis stroke	about 250  mm
	Y-axis maximum speed	30m/min
	Maximum punch diameter	Φ23mm
CNC punching machine for large web plate	Nominal force	1700kN
	Punch type	13
	Module number	21
	Y- axis stroke	about 250mm
	Y-axis maximum speed	30m/min
	Maximum punch diameter	Φ65mm
Intermediate manipulator	Maximum speed	40m/min
	X-axis stroke	about 2000 mm
Fixed wing CNC punching machine	Nominal force	650kN
	Punch type	6
	Module number	6
	Z-axis stroke	about 100mm
	Z-axis maximum speed	10 m/min
	Maximum punch diameter	Φ23mm
Hydraulic system	system pressure	24MPa
	Cooling mode	Oil cooler
Pneumatic system	working pressure	0.6 MPa
electrical system		Siemens 840D SL

 

1. Main outsourcing components list

No.	Name	Brand	Country	Remark
1	CNC	Siemens 840D SL	Germany
2	servo motor	Siemens	Germany
3	Precision linear sensor	Balluff	Germany
4	Hydraulic system	H+L	Germany
5	Other main hydraulic components	ATOS	Italy
6	linear guide rail	HIWIN	Taiwan, China
7	Wide guide rail	HPTM	China
8	Precision ball screw	I+F	Germany
9	Screw support bearing	NSK	Japan
10	Pneumatic components	SMC/FESTO	Japan / Germany
11	Single air bag cylinder	FESTO	Germany
12	Elastic coupling without backlash	KTR	Germany
13	Frequency converter	Siemens	Germany
14	computer	LENOVO	China
15	Drag chain	IGUS	Germany
16	Automatic lubrication device	HERG	Japan	Thin oil

Note: The above is our fixed supplier. It's subject to be replaced by same quality components of other brand if the above supplier can't supply the components in case of any special matter.

Work Environment:

1).Power supply:  3 phase 5 lines     380±10%V    50±1HZ
2).Compressed air pressure:       ≥0.5MPa
 3).Temperature:                 0-40°C
4).Humidity:                     ≤75%

Our company:

      Shandong FIN CNC MACHINE CO., LTD. is always focusing on our ultimate goal - to secure and increase our customer's productivity - has made us the leader in China market in the manufacture of machines for processing angle bar, beam channel profiles, steel plates, tubesheet and flanges, mainly serving for fabricating iron towers, steel structure, heat exchangers, boilers, bridges, and trucks.Strong R & D center with 30 engineers team, 24 years of experience from year 1997, 280 staff, plant area about 270,000 sqm., very harsh quality control of every component and the whole machine, about 40 million US dollars sales turnover per year.
FIN CNC machines' market share in China is around 70% and exported to 50+ countries across globe market. All top ranked tower manufacturers, steel structure fabricators and power station makers, bridge/railway manufacturers, truck makers are our clients.
Main products: CNC Angle Line, CNC Beam Drilling Sawing Machine, CNC Plate Drilling Machine, CNC Rail Processing Machine, CNC Tubesheet Flange Drilling Machine, Truck beam plate punching machine, etc..One measure of the outstanding quality of our machines is their longevity: many FIN machines have been in operation for more than 17 years! Many clients are continually placing repeated orders which verified well our machines' perfect quality and reliable performance.
The company drafted many China national standards for CNC angle line machine and CNC beam drilling sawing machine and CNC plate drilling machine.









FAQ

1. When can you arrange shipment?

For machines available in stock, the shipment can be arranged within 15 days after getting advance payment or L/C;
For machines non available in stock, the shipment can be arranged with 60 days after getting advance payment or L/C.

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1) We can send you free components if machines are in warranty period;
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Yes. We can send professional engineers to the working site for machine's installation, commissioning and operation training.

4. Which machine model shall I choose when I purchase from you?

Please share us your material size and your processing request, then we will recommend our machine most suitable and most cost effective for your work demand.

5. What's your machine's market share in China?

Our market share in China is about 70%+, and we've exported to 50+ countries across the globe market, since year 1998.