YX51- Decking

Roll forming machine

OPERATION MANUAL

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 4.1 It is required to use crane to lift Roll forming part A and B and connect them.要求

使用吊车将 AB 两段吊起来并连接好。

4.2 The factory ground where the machines are mounted must be firm and level

防止机器的地基要求牢固和平坦。

4.3 After placing the machines, lock all the connection bolts and nuts and wire

connections. 连接好机器之后，锁紧螺栓。

4.4 Adjust the position of stacker and make sure stacker is close to the post cutting.

4.5 Connct the electrical wires and cables. 连接好电缆和电线。

4.6 Fill with 46# hydraulic oil into the hydraulic tank. 加好液压油。2/3 邮箱的容积。

4.7 Install all the guarding cover around the chains/gears 安装好防护罩

4.8 Connect the Transformer/Air compressor and then Switch on the power supply.

连接好变压器和电源开关。

5. TRIAL COMMISIONNING OPERATION 试操作说明

5.1 Check if post cut blade is in the top limit position or not. And make sure cutting

blade is in top limit position, then machine can run forward or backward..检查后

剪是否在上限位。确保切刀都要在上限位，机器才能运行。

5.2 Manually press “forward”/”Backward” button let the machine run without sheet.

If no any problem, then can begin to produce products. But make sure feeding

guide is correctly locked and rollers up/down gap are correct. 手动按下正转按

钮，进行空机测试。如果没有问题，则可以进料生产。

6. FEEDING OPERATION INSTRUCTION 进料操作说明

6.1: Set and Lock feeding guide tightly. 调整并锁好进料导向。

6.2: Beore feeding the material into the feeding guide, check the material is just right

1220mm or more than 1220mm. If material width is 1220, then feeding guide is not

needed to reset, if more than 1220mm, then keep left guide not set, but reset right

side feeing guide., due to right side is a slitting wheel there in no.10 station. 将原料

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1. SAFETY ATTENTIONS:安全事项

1.1 Before operate the machine, please read the safety notes and operations

instructions. 操作机器之前，先阅读说明书

1.2 Make clear marks to warn the hazardous area and prevent persons accessing to.

机台旁边设置警告标识，以防止人员接近危险区域。

1.3 All the safety guarding cover cannot open when machine is in running. 机器运行

时，请勿打开防护罩

2. COMPONENT PARTS IN LINE 整线组成

l Hydraulic Un-coiler

l Feeding guide

l Embossing rolling

l Roll forming machine

l Hydraulic post cutting device

l Hydraulic post press device

l PLC Control System

l Hydraulic power pack

3. PROFILE PARAMETERS 板型尺寸

ITEM Parameter
Thickness 0.7-1.0 mm/1.2mm

Feeding width 1220mm

Effective width 1000mm ±5mm

Embossing flower Top/ flange side

Male lip dimension recommendation 8mm

Female lip dimension recommendation 10mm

4. MACHINE INSTALLATION 安装说明

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 塞入进料台之前，先检查原料宽度是否刚刚好 1220mm。如果是刚刚好，那么进料导

向不需要调整。如果大于 1220， 那么左边的导向保持不动，右边的导向向外调整，因

为右边有分条刀。

6.3: Close the clutch device until material pass through 10 meters long or more, then

operator can open the clutch device. (Close the clutch is to make first embossing

rollers can feed the material automatically, and open the clutch is to make sure

material not go up between first embossign roll and later stations due to speed is a

little different in front and in rear.) 开始进料时，合上离合器，持钢带进入主机 10 米左

右时松开离合器即可正常生产。离合器就在第一道的右边。松开离合器的目的是为了防

止第一道的速度比后面道次的速度快，而导致板中间挤压拱起来。

Note: before open the clutch, please push the “Backward” button to reverse 100mm,

then can open the clutch.按手动按钮倒退 10 公分左右，把离合器断开。

7.5: Let material go under the single roller(between first embossing roll and second roll),

this design is to make sure material in good forming. 料头进过第一道压轮后，需手动将

料头绕过一根光轴的下方，再进入第二道。这样做的目的是为了消除板面上的凹凸不平。

不可在光轴的上方通过。这个是特别的要求。

7.6: slitting wheel: it is set in No. 10 station right side.分条刀安装在第 10 道右边。

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7.7: Feed the material ahead and slowly enter into the post cutting. Specially remind that

operator has to supervise the profile head can go through the post blade holder. If

profile cannot completely match the blade holder, then operator has to manually

assist profile sheet pass to the blade. 第一片板经过第一道，直至后切断过程中，都必

须手动完成，特别是后切断的位置时，防止因板型撞刀，导致危险发生。因此，料头进

入后切断一定要非常慎重并要求以非常缓慢的速度点动进入。如板型与刀口有些微偏差

的时候，请手工辅助进入，并注意安全。

7.8：Press device: from post cut to press mould distance is 480mm. 刀具与冲压模具中心

距离 480mm 固定。

DOWN MOULD: Front one is fixed, can not go up/down; the other one is mobile

mould=down mould, can go up/down pushed by cylinder. Note-1: Mobile mould is for

the purpose when end press is done, mobile mould go down and let the product run

out. And one time pressing can make press on end of last piece and end of next

piece.

下模：前面一个是固定不动的，后面一个是可以上下活动的。注意；后面这个可以活动

的目的是为了当每片板的尾部压扁过后，移动的这个下模往下走，然后让压扁后的板走

出去。一次冲压可以完成前一片板的尾部，和后一片板的头部（料头除外）

Note-2: for press on end of last piece, it must be pressed by manually.How to

operate it, please follow the next steps:

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 注意 2：最后一片板的尾部，只能手动进行冲压。

End of next piece

End of last piece

① Press Down-Mould Down(means down mould go up)

Turn right side

② Press Up-mould Down(means 2 up-moulds go down at the same time)

Turn right side

③ Press Down-Mould Up(means down-mould go down for return)

Turn left side

④ Press Up-mould up, then up-mould will go up for return.

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 Turn left side

l 手动操作压模顺序：
（上）下模具（下）
，按下就是下模往上走，

l 然后（上）上模具（下）
，按下就是上模往下压。

l 然后按下模（上）
，于是下模会往下返回。

l 再按上模（上）
，于是上模会往上返回。最后板才能离开。

UP MOULD: two press go up/down together at the same time.上模有两个，同时上下

活动。

480mm

7.9: Start the hydraulic pump and cut the profile firstly. Next step is to do the production

order setting. Please read : Production Order Operation Instruction.

启动液压油泵，切断料头。接下去就是进行生产订单的设置工作。

7. MACHINE ADJUSTMENT INSTRUCTIONS 机器调整说明

7.1 Feeding table adjustment: It is well set before shipment. If material width is right

1220mm, then the table is not required to be adjusted again. If material is more

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 than1220, then only need to adjust right side of feeding guide.

进料导向的调整：出厂前调整好，通常情况下，只要原料宽度 1220mm 标准，不

再需要调整。如果板宽度偏大，则调整右边的导向。

7.2 Cutting blade adjustment: after long time use, the blade maybe worn out. Then

the blade can be dismantled to be milled and then install again. Note: operator

has to make sure top and bottom blade close and then lock all the bolts and nuts.

液压前剪的调整：通常情况下，使用时间长后，刀片的螺栓可能会送掉，定期检查

后如发现松开现象。请手动合并上下刀，让刀片互相贴紧，然后再锁紧螺栓。如果

刀片磨损了，可把刀片拆下来，拿到磨床上磨锋利后再安装回去。注意，磨刀片的

时候，刀垫片也要一起磨，否则会有台阶锁不紧。

7.3 Embossing rolls adjustment: after long time use, the embossing rollers gap may

be loosen and flower maybe not symatric, then operator can adjust the gears

as follows:

两道压筋不对称时调整，需在主机的压筋滚轮左侧，调整齿轮的位置（顺时针

或逆时针）来实现压筋的调整。

Adjust the bolt

7.4 Thickness adjustment: if material thickness is changed, then the up/down rollers

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 clearance has to be adjusted accordingly from first station to last station.

原料厚度变化时的调整：需从第一站到最后一站，上下滚轮之间的间隙均需要调整。

7.5 Limit switch adjustment: after some time use, the limit switch maybe loosen, then

operator has to check and fix the top and bottom limit in right position. If blade is

not in top limit position, then machine is not working. 切刀行程开关的调整。出厂时

都会紧固上下限位。如因机器生产一段时间后，螺丝松了会导致行程开关的位置发生

变化，这时候需要检查并定好位置，手动按切刀上下来定位行程开关的固定位置。如

果位置不当，则可能切刀不会上，或者不会下。固定好位置后，务必用内六角锁紧限

位开关，防止继续松动。

7.6 Profile sheet deviation adjustment: sometimes if operator find the profile sheet

goes to left side or right side. Then operator has to check the machine up/down

roll clearance is the same or not.Normally if left side up/down roll cleanrance

is tight, then material goes to left. Another reason maybe feeding guide is not

well wet and locked. So feeding is also required to check. 板型跑偏的调整：当

板型往一边跑的时候，第一要检查进料导向是否有正。第二就是检查各道滚轮左右

的间隙不一致。这两点都会导致跑偏的可能。如果是进料导向，那么久要重新调整

导向的位置，做到左右平行，与主机母线对中。如果是滚轮间隙导致，通常钢板都

是往间隙小的那一边跑。这时候就要重新调整丝杆，确保左右间隙一致。

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 7.7 Profile dimension adjustment: if found the profile dimension is bigger in width, then

the up/down roller clearance is big, then press the top roller in both sides so that to

ensure left side and right side is in the same clearance. Note: especially found the

profile is in very big difference from post cutting blade, then it is also required to do

adjustment on the machine rollers.

板型尺寸不符的调整：当板型有效宽度偏大，说明滚轮的间隙偏大，就需要相应调整小。

当板型有效宽度偏小，说明滚轮间隙太紧，就要适当松开间隙。一定要注意，刀口尺寸

是固定的，只能调整板型来适应刀口。否则可能导致板型切断口会变形严重。

7.8 GAP BETWEEN UP/DOWN ROLLERS: When forming different thickness, the

gap between up/down rollers should be adjusted accordingly,

Thickness 0.7mm 0.8mm 1mm 1.2mm
Gap 0.75mm 0.85mm 1.05mm 1.25mm
Bellow feeler gauge is for checking the up/down roller cleanrance (gap), its range

from 0.25mm to 2.0mm. we equippe this in the TOOLS box.

8. HYDRAULIC POWER PACK INSTRUCTIONS 液压系统说明

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1）TECHNICAL PARAMETER

DESCRIPTION SPECIFICATION

Working pressure 8MPa

Testing pressure 10Pa
Rating flow 24L/min
Capacity of oil tank 52L
Motor 18.5.5kW, 1440r/min380V/50Hz/3PH
Oil-scavenger filter RFA-40X20L-Y
Rating flow of oil-scavenger filter 40L/min
Filtrated precision of oil-scavenger filter 10u
Valve module voltage DC 24V
System cleanliness class NAS1638-8

2） OPERATION, MAINTENANCE AND ATTENTION

① Hydraulic oil type: No.46# high-class anti-wear hydraulic oil

② About the system pressure (it is done by the overflow valve): 8MPa.

Attention: the pressure has been regulated before the equipment shipment,

please don’t change the setting number, otherwise, the equipment may be

damaged.

③ Oil change: After the machine is used for a year, please change the oil when the

machine is maintained wholly.

④ Raising the pressure of system, exhaust and temperature check:

After the main pump is started, runs it under low pressure for 10~30min.

Please examine the temperature of the pump and motor at regular interval when

raise the pressure or the machine runs under the high pressure

⑤ Check the hydraulic system cleanliness class at regular interval.

⑥ ATTETION: After the hydraulic parts, the hoses, motor and oil-tank working for some

time, they will be heat, and may heat someone, so please don’t touch it.

Check it under the filtrated period

Check it under the regulation

9. ELECTRICAL OPERATION MANUALS 订单操作说明

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 10.1 Attention:
10.1.1 Please provide reliable ground wire, PLC ground wire, and motor wire.

10.1.2 Provide stable voltage.380V+10%, 3PH+ neutral wire

10.1.3 Keep encoder signal wire away from power wire to prevent interfere and

affecting measuring precision.

10.1.4 PLC atmosphere temperature ; HIM atmosphere temperature 0℃~40℃.

10.1.5 Inverter atmosphere requirement:

l temperature -10℃~40℃
l height≦1000M

l Avoid being slam strike

l Do not install inverter on the place where often shaking.

l Do not install inverter on the place where has electromagnet interference.

l Do not install inverter on the place where has big dust and etchant gas.

l Do not install inverter on the place where has big humidity.

l Make sure inverter installed in the place with good air flow to reduce heat

l Do not touch inverter when in working state.

10.2 Warnings:
10.2.1 Inverter cannot drive a motor that its rated power is more or less than half

of this motor. Only the rated currency and motor nameplate match with

each other, then inverter can run.

10.2.2 This inverter does not fit for the situation with mechanical “emergency

stop”.

10.2.3 It is forbidden to connect the output terminal (U, V, W) to the AC power

supply, to avoid injury or fire. That is to say not allow connecting the

power supply wire to the motor output terminals or otherwise inverter will

be broken.

10. . ORDER SETTING OPERATION INSTRUCTION

Switch on the power supply and touch screen shows the interface as follows:

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Click “enter” into the English and Enter interface as follows:

Can choose press

Choose press

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 Can choose

{no press}

Choose

no press

When need to do AUTO RUN, please turn the KEY to Auto.

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 Turn to Auto

Firt Compe=2, this

one can be

changed.

Regarding LINER COMP= LINEAR COMPENSATION. For example, set length is

6000mm, if every piece is 6006mm, then, （6006-6000）/6=1mm/m. That is to say,

1meter has 1mm difference. So input 1, or otherwise input-1.

关于长度补偿。LINEAR COMPENSATION:比如设置 6000，实际全部都是 6006，

那么，
（6006-6000）/6=1mm/米，也就是每米偏差 1mm。可以在补偿上输入 1，

如果是长度少了，就输入-1.

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Malfunction Disposal:
1. When manual or automatically mode cannot run, then check the cutter is not in the up limit

postion or E-stop is pressed down, not open.

2. When cutter go down, but can not go up, then check cutter no in the down limit position,

please adjust the limit switch postion

Note: when inverter is in malfunction, if press “stop” cannot recover, then can switch off the

inverter and then restart again, to recover from malfunction.

Remind once again: When material is in the machine, please do not

operate Reverse Running except Backward running 100mm for Clutch
open only.

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