Product Description

Process flow:

↗ pressure lead

Transportation → feeding → uncoiling → clamping initial bridge → transition → CZPT pressing → slitting → passing

The straight end, the shovel-end

Transit → CZPT → fine leveling → fixed ruler, tail plate clamping → crosscutting → blanking → binding and hoisting;

 

C. Equipment composition:

1. Hydraulic charging trolley: load bearing 8T;

The car can carry steel coil moving and lifting.The car is mounted above the ground level.

The lifting of trolley table is completed by oil cylinder, and the moving power of trolley is motor, which can move 2000mm

Small 4 wheel, wheel diameter ф 180 mm material 45, surface quenching HRC45 ~ 48 °;

Surface of roller diameter ф 130, 2 root, polyurethane glue;

Axle material: 40Cr quench HB230 ~ 250;

Lifting oil cylinder Ф 140 x 550 mm;

Running motor: bwed-b121-1.5kw I =121 cycloidal needle wheel motor;

The frame is a welded structural part which has been treated with stress relief.

 

Hydraulic loading car: bearing Max holing 8T;

The car can carry steel coil moving and lifting.Move and lift coil. Installed on floor

Lifting of trolley table is completed by oil cylinder, and the moving power of trolley is motor moving

By motor can move 2000mm.

Four little wheels and wheel diameter diameter ф 220 mm wheel, 4 wheels and qualitative material type 45, surface quenching surface quenching HRC45 ~ 48 °;

Xihu (West Lake) Dis. pin diameter of the column diameter ф 110, 4 4 pierces, tempering tempering HB230 ~ 250

Shaft material 40Cr tempering HB230 ~ 250;

Lifting oil cylinder lifting oil cylinder Ф 220 x 800 mm;

Running motor: BWED-B142-3kw I =121 cycloid needle wheel motor needle motor

The frame is a welded structural part which has been treated with stress relief.Stand is welded structure.

 

 

2. Hydraulic single-arm expansion feeder: load bearing 8T

It is composed of base, frame, feeding shaft, pull rod, expanding feeding plate, hydraulic expanding mechanism, expanding and shrinking oil cylinder, sliding mechanism, supporting uncoiling motor, reducing gear, braking mechanism and so on.

The base and frame are welded structural parts which have been treated with stress relief.

Feeding spindle material 40Cr quench HB230 ~ 250;

Applicable width: 50-400mm; 

Applicable scope of inner hole: 508, ф ф 610;The ф 610 inner hole plate;

Brake model: ywz300/45;

 

3. Straight head pressing mechanism:

The hydraulic pressure straightening head mechanism is installed on the feeder, which is matched with the swing hydraulic pressure CZPT arm, the pressure CZPT rubber wheel, the chain and sprocket, and the bwed-b131-121-3kw two-stage cycloidal needle wheel reduction motor.

Two pressure CZPT cylinder ф 80 x 350 mm;

Hydraulic straight head mechanism is roller type, with a length of 500mm;Material 40Cr surface quenching HRC42 ~ 45;

Straight hair grease cylinder specification: ф 90 x 400 mm;

 

4. Hydraulic shovel, balancing mechanism:

It is composed of hydraulic telescopic spatula, spatula frame, hydraulic spatula head mechanism and balancing mechanism.

Shovel head telescopic cylinder specification: ф 63 x 450 mm;

Two shovel head balance cylinder specification: ф 80 x 350 mm

 

5. Clamping initial straightening unit:

Consists of the power part and the main engine part:

Power part:

It is composed of frame, 5.5kw ac motor, reducer, gear, gear shaft, clutch, coupling and so on.

(2) main part:

It is composed of frame, frame, 2 clamping rollers, 3 initial straightening rollers, sliding shaft seat, lifting and pressing down mechanism, hydraulic lifting and pressing down mechanism of upper clamping traction roller, and hydraulic lifting and pressing down mechanism of upper straightening roller. 

Pinch roll flattening ф 160 mm diameter, material of 40 cr, the surface of the intermediate frequency quenching HRC52 ~ 55.Effective width of clamping roller: 500mm;

Two pinch cylinder sizes ф 80 x 180 mm;(two synchronizations)

At the beginning of the 2 dresses cylinder sizes ф 90 x 200 mm;(two synchronizations)

 

6. Raceway table: 3m, 1 piece;

It is composed of work stand, supporting plate, roller table, bearing seat, etc.

 

7. Xihu (West Lake) Dis. (press roll) mechanism

By the CZPT rail type machine base, sliding seat, vertical wheel four, mechanical adjustment mechanism, up and down pressure roller mechanism.

Middle range of CZPT pair: 50-500mm;

Wheel material 50Cr, surface quenching hardness hrc54-58.

Vertical roll specifications: Ф 120 x 150 mm.

Roller specification: Ф 90 x 600 mm.

 

8. Slitting unit:

The power part consists of power frame, ZQ750 high strength steel plate welding reducer, 75kw dc speed regulating motor, coupling, clutch, tooth distribution box, shaft socket, universal joint and so on.

Main engine part: it is composed of frame, fixed cast steel frame, cast steel slider, 2 cutter shafts, cast steel movable frame, cast steel slider, hydraulic front and rear adjustment mechanism of the rack, lifting and lowering adjustment mechanism of the cutter shaft, supporting 2.2kw cycloidal needle wheel reduction motor, spacer, rubber ring, etc.

Deceleration type: ZQ750 I = 31.5;

Motor model: z4-225-11 75kW 1000r/min;

Universal joint model: swc-200 25kN•m;

Width of effective loading tool for slitting: 550mm;

Knife shaft diameter: Ф 200, 50 cr material;

The blade specifications: Ф 20, 320 x 200 x Ф user distribution;

Knife pad specification: 200 x Ф Ф 260 x 1100 mm is the total length of H (H);

Rubber ring specifications: 1, 320 x 260 x Ф Ф H, H1 + H2…= 550 mm;

2, Ф 315 x 260 x Ф H, H1 + H2…= 550 mm;

 

9. Edge-wire interrupting mechanism:

It is composed of a frame, a wire-edge cutter shaft, a wire-edge interrupting disk, an aggregate box, a CZPT wire mechanism, and a shaft coupling, a deceleration mechanism and a motor.

 

10. Raceway table: 3m long

It is composed of work stand, supporting plate, roller table and bearing seat.

 

11. Xihu (West Lake) Dis. mechanism

It is composed of CZPT rail frame, sliding seat, vertical wheel, mechanical adjusting mechanism and idler mechanism.

Middle range of CZPT pair: 50-500mm;

Wheel material 50Cr, surface quenching hardness hrc54-58.

Vertical roll specifications: Ф 120 x 150 mm.

 

12. Roller clamping mechanism:

It is composed of frame, frame, 2 clamping rollers, fixed shaft holder, sliding shaft holder, lifting and pressing mechanism of upper roll, hydraulic adjusting mechanism of upper clamping roller, etc.

Pressure is expected to roll diameter: Ф 130;Material: 40 cr

Effective width of pressing roller: 500mm;

Two pinch cylinder sizes ф 63 x 120 mm;(two synchronizations)

 

13. Precision leveling unit: one

The power part: by the power base, high strength steel plate welding reducer, 75KW dc speed motor, motor wheel, coupling, YWZ brake, power distribution box, 6 groups of shaft socket, 5 10 bytes of universal.

(2) the main engine part: by the frame, frame, beam, lower shaft seat, sliding shaft seat, 11 leveling rollers, upper press frame, upper and lower support wheel seat adjustment mechanism, upper and lower support wheel seat each group, support wheel each group, machine ruler indication, supporting pressure down positive motor 2, lubrication pump 2 and so on.

The roller of our company is made of 42CrMO, which is made by forging, processing, tempering, processing, quenching.

The leveling machine adopts gear distribution box to improve the strength and service life of the gear. It is connected with each leveling roller with 10 bytes of universal direction. Both the upper and lower leveling rollers are driving shafts with the same linear speed.

Two sets of large roller bearings and 1 set of plane thrust bearings are used at each end of the leveling shaft to reduce friction, prevent axial movement and improve leveling quality.

The levelling machine adopts worm gear and worm gear, with large torque adjustment under double deceleration pressure and strong pressure down force, which can be adjusted independently and simultaneously, and can also be adjusted manually.

The main shaft is leveled by centralized oil supply, which is convenient to use and can avoid burning the bearing due to lack of oil, thus improving the service life.

Leveling roll ф 130 mm diameter, material: 42 crmo;

Effective width of flattening roller: 500mm;Medium frequency quenching hardness hrc57-60 °;

Supporting wheel material 40Cr, surface quenching hardness hrc52-54 °

Steel plate welding reducer model ZQ750, I = 23.34;

Motor model: z4-200-11, 75kw, 1500r/min;

Press down adjustment motor: bwd-b12-29-1.5kw 2;

Strength universal joint model: swc-125 nominal torque: 5KN/m;

14. Code sizing mechanism: 1 set

It is composed of coding seat frame, coding connection mechanism, encoder, etc.

15. Plate cutting machine: one

It is composed of frame, frame, fixed tool holder, upper and lower tool holder, CZPT rail, synchronous mechanism, press foot, hydraulic cylinder and so on.

Effective shear width 600mm;

Material: H13K, thickness: 24mm, hardness: hrc56-58 °

16. Unloading table:

It is composed of unloading stand, supporting plate, power roller table, chain, sprocket and bearing seat.

Discharge power roller table is driven by motor to send out the production line;

Discharging motor model: bwd-b13-35-3kw;

Discharge form: after discharge;

17.Electronic control system:

Power supply and distribution system: power input voltage: three-phase Ac380V 50Hz

Control voltage: Ac220V 50Hz hydraulic voltage: Dc24V

The electronic control system of leveling production line is composed of 2 dc cabinets, 1 main operating cabinet and 1 secondary operating cabinet.The dc motor is equipped with the imported all-digital dc speed regulating device (euro590p), and the cabinet is controlled and communicated by PLC. The touch screen is used to carry out man-machine dialogue (the number of shear plates and the setting of any length), so as to control the operation of the whole unit.According to the motion state can be divided into linkage and manual.Manual operation for control of each single machine.

The equipment is equipped with safety protection, emergency stop and power off button, stop display lamp and other devices.

18.Hydraulic pneumatic system:

Hydraulic system is an important part of the production line, is 1 of the power source of the production line.

The hydraulic system consists of hydraulic pump, valve plate, hydraulic reversing valve, overflow valve, pressure retaining valve and adjusting valve, high pressure soft and hard pipe, joint and so on.

Hydraulic power supply power: 11kw

Rated working pressure: Pmax=16Mpa, flow rate: 40L/min

General working pressure: ≤ 10-12mpa

Operating oil temperature: -5~70° box volume: 1.1m

 

D. requirements:

1.Power supply voltage 380V± 10%, frequency 50Hz± 10%;

2.Operating environment: applicable to -10ºC, humidity 20%-80% (no condensation);

3.Protection class, electrical control cabinet, console: IP40;

4.Air pressure: 0.6-0.8mpa (anhydrous).

 

E. Unit lubrication:

The main gear box and power distribution box can be refuelled to the lower gear root (add gear oil), new

Change the oil once a month after the car runs.

Reducer and gear oil to the oil standard, the new car after running a month to replace the oil.

Press down adjustment worm gear, worm, bearing grease (butter).

Each flattening roller bearing, supporting wheel bearing with mixed oil (winter 1 grease 2 machine

Oil, 2 parts grease and 1 part oil in summer) 3 times per shift

 

Vii. Price of the complete set of equipment:

Viii. Production cycle: 100 working days.

Applications of Spline Couplings

A spline coupling is a highly effective means of connecting 2 or more components. These types of couplings are very efficient, as they combine linear motion with rotation, and their efficiency makes them a desirable choice in numerous applications. Read on to learn more about the main characteristics and applications of spline couplings. You will also be able to determine the predicted operation and wear. You can easily design your own couplings by following the steps outlined below.

Optimal design

The spline coupling plays an important role in transmitting torque. It consists of a hub and a shaft with splines that are in surface contact without relative motion. Because they are connected, their angular velocity is the same. The splines can be designed with any profile that minimizes friction. Because they are in contact with each other, the load is not evenly distributed, concentrating on a small area, which can deform the hub surface.
Optimal spline coupling design takes into account several factors, including weight, material characteristics, and performance requirements. In the aeronautics industry, weight is an important design factor. S.A.E. and ANSI tables do not account for weight when calculating the performance requirements of spline couplings. Another critical factor is space. Spline couplings may need to fit in tight spaces, or they may be subject to other configuration constraints.
Optimal design of spline couplers may be characterized by an odd number of teeth. However, this is not always the case. If the external spline’s outer diameter exceeds a certain threshold, the optimal spline coupling model may not be an optimal choice for this application. To optimize a spline coupling for a specific application, the user may need to consider the sizing method that is most appropriate for their application.
Once a design is generated, the next step is to test the resulting spline coupling. The system must check for any design constraints and validate that it can be produced using modern manufacturing techniques. The resulting spline coupling model is then exported to an optimisation tool for further analysis. The method enables a designer to easily manipulate the design of a spline coupling and reduce its weight.
The spline coupling model 20 includes the major structural features of a spline coupling. A product model software program 10 stores default values for each of the spline coupling’s specifications. The resulting spline model is then calculated in accordance with the algorithm used in the present invention. The software allows the designer to enter the spline coupling’s radii, thickness, and orientation.

Characteristics

An important aspect of aero-engine splines is the load distribution among the teeth. The researchers have performed experimental tests and have analyzed the effect of lubrication conditions on the coupling behavior. Then, they devised a theoretical model using a Ruiz parameter to simulate the actual working conditions of spline couplings. This model explains the wear damage caused by the spline couplings by considering the influence of friction, misalignment, and other conditions that are relevant to the splines’ performance.
In order to design a spline coupling, the user first inputs the design criteria for sizing load carrying sections, including the external spline 40 of the spline coupling model 30. Then, the user specifies torque margin performance requirement specifications, such as the yield limit, plastic buckling, and creep buckling. The software program then automatically calculates the size and configuration of the load carrying sections and the shaft. These specifications are then entered into the model software program 10 as specification values.
Various spline coupling configuration specifications are input on the GUI screen 80. The software program 10 then generates a spline coupling model by storing default values for the various specifications. The user then can manipulate the spline coupling model by modifying its various specifications. The final result will be a computer-aided design that enables designers to optimize spline couplings based on their performance and design specifications.
The spline coupling model software program continually evaluates the validity of spline coupling models for a particular application. For example, if a user enters a data value signal corresponding to a parameter signal, the software compares the value of the signal entered to the corresponding value in the knowledge base. If the values are outside the specifications, a warning message is displayed. Once this comparison is completed, the spline coupling model software program outputs a report with the results.
Various spline coupling design factors include weight, material properties, and performance requirements. Weight is 1 of the most important design factors, particularly in the aeronautics field. ANSI and S.A.E. tables do not consider these factors when calculating the load characteristics of spline couplings. Other design requirements may also restrict the configuration of a spline coupling.

Applications

Spline couplings are a type of mechanical joint that connects 2 rotating shafts. Its 2 parts engage teeth that transfer load. Although splines are commonly over-dimensioned, they are still prone to fatigue and static behavior. These properties also make them prone to wear and tear. Therefore, proper design and selection are vital to minimize wear and tear on splines. There are many applications of spline couplings.
A key design is based on the size of the shaft being joined. This allows for the proper spacing of the keys. A novel method of hobbing allows for the formation of tapered bases without interference, and the root of the keys is concentric with the axis. These features enable for high production rates. Various applications of spline couplings can be found in various industries. To learn more, read on.
FE based methodology can predict the wear rate of spline couplings by including the evolution of the coefficient of friction. This method can predict fretting wear from simple round-on-flat geometry, and has been calibrated with experimental data. The predicted wear rate is reasonable compared to the experimental data. Friction evolution in spline couplings depends on the spline geometry. It is also crucial to consider the lubrication condition of the splines.
Using a spline coupling reduces backlash and ensures proper alignment of mated components. The shaft’s splined tooth form transfers rotation from the splined shaft to the internal splined member, which may be a gear or other rotary device. A spline coupling’s root strength and torque requirements determine the type of spline coupling that should be used.
The spline root is usually flat and has a crown on 1 side. The crowned spline has a symmetrical crown at the centerline of the face-width of the spline. As the spline length decreases toward the ends, the teeth are becoming thinner. The tooth diameter is measured in pitch. This means that the male spline has a flat root and a crowned spline.

Predictability

Spindle couplings are used in rotating machinery to connect 2 shafts. They are composed of 2 parts with teeth that engage each other and transfer load. Spline couplings are commonly over-dimensioned and are prone to static and fatigue behavior. Wear phenomena are also a common problem with splines. To address these issues, it is essential to understand the behavior and predictability of these couplings.
Dynamic behavior of spline-rotor couplings is often unclear, particularly if the system is not integrated with the rotor. For example, when a misalignment is not present, the main response frequency is 1 X-rotating speed. As the misalignment increases, the system starts to vibrate in complex ways. Furthermore, as the shaft orbits depart from the origin, the magnitudes of all the frequencies increase. Thus, research results are useful in determining proper design and troubleshooting of rotor systems.
The model of misaligned spline couplings can be obtained by analyzing the stress-compression relationships between 2 spline pairs. The meshing force model of splines is a function of the system mass, transmitting torque, and dynamic vibration displacement. This model holds when the dynamic vibration displacement is small. Besides, the CZPT stepping integration method is stable and has high efficiency.
The slip distributions are a function of the state of lubrication, coefficient of friction, and loading cycles. The predicted wear depths are well within the range of measured values. These predictions are based on the slip distributions. The methodology predicts increased wear under lightly lubricated conditions, but not under added lubrication. The lubrication condition and coefficient of friction are the key factors determining the wear behavior of splines.