The 40 ton paired roller frame mainly consists of HGK40 adjustable electric walking roller frame and ZDHGK20 hydraulic paired roller frame.
HGK40 adjustable electric walking roller frame
1 Overview
The HGK series adjustable welding roller frame is widely used in the manufacturing industries such as boilers, pressure vessels, petroleum, chemical, and machinery for automatic welding or grinding of the inner and outer longitudinal and circumferential seams of boiler drums, steam drums, and other cylindrical components. It has advanced structure, complete functions, easy operation, and plays a reliable guarantee role in improving product quality.
1.2Structural characteristics The HGK40 adjustable electric walking roller frame is mainly composed of an active roller frame, a passive roller frame, an electronic control system, etc. The active roller frame is driven by two AC motors, which respectively drive two reducers. The output end of the reducer is coaxial with the roller shaft (the output shaft of the reducer is a hollow shaft), thereby directly driving the rollers. The driving reducer adopts a cycloidal pinwheel reducer+gear reducer structure to ensure that the workpiece can be driven to operate. The motor is driven synchronously by two AC motors, and the reducer adopts a self-made cycloidal pinwheel and gear reducer. This reducer has a more compact structure and stronger driving ability than the standard reducer. All gear shafts of the drive reducer are made of 35CrMo material, and the large gear is made of 40Cr material, all of which have undergone processes such as quenching and tempering and tooth surface quenching. The rubber wheel is made of polyurethane, which has good oil resistance, toughness, wear resistance, and aging resistance. Using imported polyurethane, its tensile strength, tear strength, wear resistance and other properties are higher than ordinary rubber, especially suitable for wind tower production lines and stainless steel cylinder processing. The roller frame base is welded from sheet metal and has high strength, ensuring long-term use without deformation. There is an electric walking mechanism installed below the roller frame, which synchronously drives the roller frame to walk on the track through two reducers. It adopts dual motor synchronous drive, and the motor has been professionally tested before leaving the factory. The rotation characteristics are basically the same, ensuring the stability of the roller frame walking. The center distance of the roller is adjusted through screw holes to adapt to the requirements of different diameters of the cylinder. The electronic control system mainly consists of an electrical control box and a wireless remote control box. The interior of the electrical control box is composed of frequency converters and low-voltage components. The main key electrical components are Schneider brand, which has reliable performance and easy maintenance. Mainly used to control the on/off of motors to achieve mechanical actions required by processes, and to control and protect roller motors. The speed control system adopts Schneider brand low-noise, high-performance, multifunctional frequency converter, which has wide range, constant torque speed regulation characteristics, smooth speed regulation, no torque pulsation and other characteristics. Its control signal adopts analog control, with high overall stability and strong anti-interference ability. The electronic control system is equipped with a wireless remote control box to ensure reliable use.
2, ZDHGK20 type 20T fixed adjustable hydraulic group roller frame 2.1 Overview The ZDHGK series roller frame is widely used in the manufacturing industries such as wind towers, boilers, pressure vessels, petroleum, and chemical industries for automatic welding of cylinder sections, steam drums, and other cylindrical components, as well as inner and outer circumferential seams. It has advanced structure, complete functions, easy operation, and plays a reliable guarantee role in improving product quality.
2.2 Structural Features The ZDHGK20 hydraulic lifting roller frame is mainly composed of a roller seat, a base, a walking mechanism, a hydraulic system, an electronic control system, etc. The roller seat is composed of rubber wheels, shafts, roller seats, etc. The roller frame base is welded from sheet metal and has high strength, ensuring long-term use without deformation. The roller rubber is made of polyurethane, which has good oil resistance, toughness, wear resistance, and aging resistance. Using imported polyurethane, its tensile strength, tear strength, wear resistance and other properties are higher than ordinary rubber, especially suitable for wind tower production lines and stainless steel cylinder processing. The center distance of the roller is adjusted through screw holes to adapt to the requirements of different diameters of the cylinder. The height of the rollers on the roller frame is achieved through the extension and contraction of a hydraulic cylinder, which can lift and lower a single cylinder and has a correction function. Adopting an independent hydraulic pump station system, key hydraulic components such as pumps and valves are selected from top domestic manufacturers. The hydraulic system operates stably, the quality of hydraulic components is reliable, and there are no leaks in the pipelines. The hydraulic pump station consists of a hydraulic pump station, hoses, pressure maintaining valves, hydraulic cylinders, etc. The electronic control system mainly consists of an electrical control box and a wireless remote control box. The electric control box is composed of contactors, buttons, etc., mainly used to control the on/off of the motor to achieve the mechanical action required by the process, and to control and protect the roller motor. The main low-voltage electrical components adopt Schneider's well-known brand products, which have safe and reliable performance. There is a power indicator on the electrical control box. On the manual control box panel, there are: roller center distance adjustment switch, and start and stop buttons for the oil pump. The four rollers movement control switch adopts a self resetting toggle switch. When the toggle switch is released, the switch automatically returns to the middle position, and the rollers stop moving. The four rollers can move separately or in linkage, with the ability to adjust the up and down of a single cylinder and the function of correcting deviation. The electronic control system is equipped with a wireless remote control box to ensure reliable use. The control box and pump station are integrated for easy transportation.
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