DXP15-250 Unidirectional Magnetic Field Press

1. Main parameter:

Press tonnage------------------------------------- 15t

Pole diameter--------------------------------- Φ250

Pole head diameter ---------------------------- Φ150

Pole distance―――――――0～200mmcontinuously adjustable

Magnetic field (40mm air gap) -------------------------- ≥20000G

Upper cylinder (main pressure cylinder) stroke --------------180mm

Side cylinder (clamping cylinder) stroke --------------------130mm

Press speed------------------------------40-50mm/s

Return speed------------------------------60-70mm/s

Single mode cycle speed ---------------------------- ≤9s

Rated power---------------------------------- about 25kW

Rated pressure of hydraulic system ------------------------ 15MPa

2. Installation condition:

The anchor hole 4-Φ26, should be fixed, and needs to be leveled basically.

The layout is arranged according to the floor area of the machine and the actual site.

The general layout is as follows: the hydraulic station is at the right rear of the main engine, and the electric control cabinet is in front of the right side of the main engine.

The power supply incoming line requires three-phase+ zero line+ ground wire. The air switch and wire diameter are selected according to the total power. The recommended value is: 100A air switch, 10mm² phase line.

The hydraulic system requires about 170kg of 46 # anti wear hydraulic oil, which is added through the filter above the oil tank cover.

The electromagnet and hydraulic station of the machine are equipped with coolers, which can work continuously only by connecting the cooling circulating water；the outer diameter of the cooling circulating water inlet and outlet nozzles are all Φ26; all the inlet and outlet water are below the rear side of the main engine.

3. Structure principle：

This machine is composed of three parts: main engine, electric control and hydraulic pressure.

3.1 Main engine

It is mainly composed of base, electromagnet, oil cylinder and so on. The electromagnet is the core of the magnetic field. When the electromagnetic coil passes through the current, the magnetic circuit formed by the yoke and the pole generates a space magnetic field with relatively parallel magnetic force lines between the two pole heads, so as to achieve the purpose of magnetic particle orientation. The oil cylinder is controlled by the hydraulic system to realize actions such as pressing, returning, clamping, and releasing.

3.2 Electronic control part 

It is mainly composed of cabinet body, operation panel, PLC and related components, DC power supply and related components, sensors, etc. The PLC of this machine adopts LS power generation k7M - DR30 Å E30 point controller, and all actions are centrally controlled by the PLC. The direct current power supply provides the electromagnet with continuously adjustable forward and reverse direct current. The sensor of this machine has a proximity switch, which serves as a limit position and safety protection for the oil cylinder.

3.3 Hydraulic press part

It mainly comprises an oil tank, oil pump, integrated block, hydraulic valve, etc. This oil pump adopts a single stage vane pump with a rated pressure of 21MPa. There are four types of hydraulic valves: electromagnetic directional valve, electromagnetic overflow valve, stacked shut-off valve, and one-way valve. The electromagnetic valve is controlled by the electric control system to change the direction of the pressure oil flow and realize the control of oil cylinder.

4. Operation Method

4.1 Action program

This machine has two working modes, which are controlled by PLC. In manual mode, each action is generally used for adjustment and maintenance, while automatic mode is used for normal continuous operation.

The operation procedure of automatic mode is as follows: (the movement in brackets is taken as manual operation)

(Loading mold is placed between the two poles with adjusted spacing, press the “cycle” button)→side cylinder entry and clamping mold→ The orientation begins and reaches its maximum →Upper cylinder and lower pressing →maintain pressure → demagnetization→upper cylinder up →side cylinder back →（take the mold）

4.2 Operation procedures

4.2.1 Startup steps

Verify that the machine is trouble free→

Press the “power switch” button on the operation panel of the electric control cabinet→

Press “pump line” button and confirm that the oil pump motor is started→

Enter normal operation

4.2.2 At work

Confirm that the “manual/automatic” transfer switch is set to the “automatic”→

The operator put the mold in the working position correctly and then leaves the hands→

Clik the “cycle” button→

The press operates according to the preset program→

Take out the mold after the last action of the press “upper cylinder”stops→

Complete a suppression

4.2.3 Shutdown procedure

Press the “pump stop” button to turn off the oil pump motor→

Press the “power” button to turn off the panel power→

4.3 Adjustment method

4.3.1 Pressure adjustment

Turn on the machine step by step→

Set the “Manual/automatic” transfer switch to “manual”→

Put the mold or substitute in the working position correctly and then leave the hand→

Press and hold the “upper cylinder ⬇”button until the mold or substitute is pressed→

The pressure gauge shows the current pressure→

Rotate the hand wheel of the solenoid relief valve at the bottom right of the pressure gauge to change the pressure→

(Read from the pressure gauge in the direction of large and reverse small)

4.3.2 Orientation, demagnetization current adjustment

Turn on the machine step by step→

Set the “manual/automatic” transfer switch to “manual”→

Clamping die or non-magnetic block between two poles→

Turn the potentiometer counter clockwise to zero→

Press the “orientation” button and rotate the orientation potentiometer clockwise to gradually increase the orientation current from zero; the demagnetization current adjustment method is the same as above.

Special attention:

The orientation adjustment potentiometer is in the operation panel, and the demagnetization micro adjustment potentiometer is outside.

Standard value of orientation current 70A, maximum 75A

The maximum demagnetization current is 30A, which can be adjusted as required.

4.3.3 Limit switch adjustment

The proximity switch is used as the limit position of the oil cylinder. The sensing head of the proximity switch should be adjusted to 1-3mm far away from the disc of the guide rod head and fixed in advance. The proximity switch seat should be move up and down according to the need, and locked with the jacking screw after it is in place.

4.3.4 Pole spacing adjustment

The left pole head is adjusted by the handwheel, forward and backward; The right pole head is driven by the right oil cylinder. Place the "manual/automatic" switch in manual mode, press the "side cylinder ↑" button to enter the side cylinder, and press the "side cylinder ↓" button to exit the side cylinder.

Adjust the position of the left pole head according to the width of the mold, so that the mold can be centered when it is close to the left pole head; Touch the side cylinder and make the right pole is 1-2mm away from the other side of the centered mold, then tighten the two large top screws on the flange of the side cylinder, and lock the lock nut of the top screw when it is in place.

4.4 Matters needing attention

4.4.1 Observe the operation rules and ensure the safety of the person.

4.4.2 Each adjustment shall be carried out by a specially assigned person and shall not exceed the limit or miss the steps.

4.4.3 In case of equipment failure during operation, it shall be handled as follows:

Press "emergency stop" button→

Observe and remove the fault or shut down the machine in normal order for repair

Special attention: Do not turn off the power directly

4.4.4 The front and rear doors of the electric control cabinet should not be opened casually to prevent electric shock.

4.4.5 Before turning on and off, the current state must be verified.If the fault is not removed, the machine can’t be turned on, and the machine can’t shut down until the action is over.

5. Maintenance and repair

5.1 Routine maintenance

5.1.1 Special personnel shall be designated to regularly check the electrical and hydraulic components and their connections and wiring, and timely replace or fasten them in case of damage and looseness.

5.1.2 Pay attention to the temperature of the electromagnet shell at ordinary times, if the hand feeling is obviously higher than the normal value, check it according to the following steps:

Power on→

Set manual→

Clamping die or non magnetic block between pole→

Press "orientation" button until the current rises to a stable value→

If it exceeds 75A, it should be adjusted to below 75A according to the regulations→

If it is less than 75A, check whether the cooling water is unobstructed, including the total water in and out and the water in and out of each group of water discharge, so as to ensure the complete patency

5.1.3 Clean the oil pump filter once a year (take it out from the filter hole above the tank cover)

5.1.4 The hydraulic oil is filtered or replaced every two years.

5.1.5 If the cooling circulating water is not softened, the acid washing water should be discharged once a year.

5.2 Troubleshooting

5.2.1 Unable to power on

Check the power supply (main power supply, cabinet power supply, panel power supply) and all air switches→

Check the "pump on" and "pump stop" buttons and the oil pump motor contactor →

If the input and output voltage in the cabinet is normal, check the motor and wiring finally.

5.2.2 No action after startup

Wether to press “emergency stop” button ( unlocking is normal) →

Check the status of the “Manual/automatic” transfer switch→

Check wether the wiring of each button and switch is loose→

Check all fuses and wiring→

Check the status of PLC( POW and RUN lights are normal) and wiring→

Check the wiring of each terminal

5.2.3 Stop the action

Check the power supply→

Wether the 'Emergency Stop' button is touched by mistake→

Is the orientation current lower than 70A (standard value 75A)→

Check all fuses and wiring→

Check PLC status (POW and RUN lights are normal) and wiring→

Check the wiring of each terminal

5.2.4 The orientation and demagnetization current decrease or disappear

First judge whether there is a problem with orientation or demagnetization. If one of them is normal, check the adjusting potentiometer and contactor of the other circuit; if both are abnormal, check the following steps:

Observe whether there is red light on the trigger board, and if there is, it means phase loss→

Check all fuses and wiring→

Check the three thyristor modules→

Check power transformer, synchronous transformer and wiring→

Check potentiometer, contactor and wiring→

Check and arrange rectification circuit→

Generally, the insulation degree of the swing coil should be more than 200MΩ

5.2.5 The pressure of the hydraulic system is unstable, reduced or disappeared

Check oil quality, oil level and oil filter at the pump suction

Check the oil inlet and outlet of oil pump for air leakage and oil leakage

Check and clean the relief valve

Check the solenoid valve and its related lines

Check whether the oil pump, motor and coupling are damaged

Check the seal of oil cylinder piston and guide sleeve

Special attention:

If you have any questions during maintenance, please do not rush to take action. Please contact our company for technical support.

6. PLC Program:

The PLC of this machine adopts LS Power MASTER 1-k120S series! Programmable controller, adopts ladder diagram programming.

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