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Cooling Steel Panel Radiator Production Line Fin Width 480mm Stable Radiator Structure

Categories Radiator Production Line
Place of Origin: Taiwan
MOQ: 1 set
Packaging Details: Neutral,sea or air worthy packing
Model Number: RV-20E
Price: Negotiatable
Payment Terms: 100% Cash in advance, but negotiatble as large purchasing
Supply Ability: Depending
Delivery Time: Depending
Transmission Type: RV
Rotate ratio/Axle rotate: 57-161
Rotate ratio/Shell Rotate: 56-160
output torque: 124-231
input capacity: 0.16,0.35,0.50,0.70
Allowed torque as starting and stop: 412
Allowed torque momentarily: 833Nm
Allowed output speed: 75r/min
Idle: 1.0arc.min
Allowed moment: 882Nm
Max.Allowed Moment instantly: 1764Nm
Inertia Moment input axle conversion: 2.39 to 9.66kgm2
Weight: 4.7Kg
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    • Product Details
    • Company Profile

    Cooling Steel Panel Radiator Production Line Fin Width 480mm Stable Radiator Structure

    Technical Details of

    Automatic Production Line for Transformer Radiator


    The transformer radiator line is special for radiator roll pressing & forming and welding line automatically. This line can be used to produce radiator fin with width in between 320mm and 540mm, such as 535mm, 520mm, 480mm, 310mm (as per user’s request) and center distance 500-4000mm.


    I. General introduction

    1. Profile

    The panel profile is a unique design, providing efficient flow characteristics and a stable radiator structure to facilitate manufacturing. The formed profile is compatible with 310, 480, 520 and 535mm panel widths. The 320mm panel model consists of 3 formed flutes that allow for 4 oil channels to be produced. The 480mm panel model consists of 5 formed flutes with an output of 6 oil channels, and the 520mm and 535 model uses 6 formed flutes to produce 7 oil channels.

    2. TECHNICAL SPECIFICATION AND REQUIREMENT

    2.1 Product specification: Sheet width: 310mm, 480mm, 520mm and 535mm (based on user’s requirement).

    Production Capacity: the complete line is not less than 35 set /hour (based on center distance 2000mm radiator)

    2.2 Center distance: 500mm- 4000mm.

    2.3 Error of center distance: ±0.5mm.

    2.4 Sheet material: high quality cold rolled coil, material quality: ST12-14, SPCC,DC01-03, SUS316, thickness: 0.8mm—1.2mm, Max. width of material: 545mm.

    For the purposes of this document and productivity calculations, the entire automated line.

    Diagram:


    PS:Regarding the end stamping (short side) process, the designing of this line is punching the short side firstly, and then weld the short side seam by Argon Arc welding, the welding surface can cover the end surface of short side, form the round corner. It also meets the latest National standard of Transformer Radiator.

    If weld the short side seam firstly and then shear (Trim) the welded short side, it will leave the very tiny space at the end of short side, when the radiator standing (installed on Transformer), the water (such as rain waiter) will bring the rust at the end of short side easily.


    3 Equipment includes.

    1. Roll pressing & forming machine (loading trolley, decoiler)

    2. Formed sheet combining and turning device

    3. Multiple spot welding unit (6-spot, Servo tracking welding for radiator tail)

    4. Long side seam welding unit (2 sets)

    5. Long side rolling shearing unit (with scrap collector device)

    6. End Stamping and Punching unit for short side (with cutter)

    7. Argon arc welding unit for End Stamping (short side) Welding (4 sets)

    8. Auto sheet unloading unit (with discharge trolley)

    9. Transmission guide rail system

    10. Operation consoles

    11. Hydraulic System

    12. Cooling water system

    13. Electrical controlling system

    14. CNC Hole punching machine for header pipe

    15. Burr grinding unit for inner surface of header pipe

    16. Assembly Fixture – Horizontal Type

    17. Flange to Header Pipe Assembly Fixture


    (Flange to Header Pipe Assembly Fixture,as Refer) (Horizontal Type Assembly Fixture, as Refer)

    4. Radiator Production Line


    4.1. AUTOMATICAL ROLL FORMING UNIT

    Consists: Loading trolley, De-coiler, Roll forming machine (with pressing roller and punching Composite die), Control Console, Hydraulic Station and Electrical cabinet and Roller press forming machine.

    Roll forming Speed: the complete line is not less than 110 pieces/hour (based on center distance 2000mm radiator)

    4.1.1 Hydraulic Decoiler

    Max. coil OD.: 1500mm.

    ID change range: 480-520mm.

    Coil weight: max. 5000kg.

    Decoiler is made of welded steel structure frame. The head of decoiler is equipped with anti-wear bearings.

    Looper control monitoring the looper between decoiler and hydraulic forming machine photosensor with photosensor.


    4.1.2 Roll Forming Machine

    Sheet Width: 310mm, 480mm, 520mm, 535mm.

    Sheet length: 500-4000mm.

    Output: speed adjustable, no less than 110 pcs/h(center distance= 2000mm).

    Roll forming machine is equipped with hydraulic cylinder. This device is driven by AC motor and adopt frequency control of motor speed.

    Movement of this device is controlled by PLC and technical length of each parts is controlled by encoder. PLC also controls pressing machine and de-coiler. User just input requirement for sheet spec, length and quantity on the touch screen, machine will running automatically according to your input data and stop production automatically after reach input quantity.


    The sheet after rolling will be put into straightener to make it straight and then feed it into press machine. Formed sheet will be feed to the guide No.1 on sheet combined overturning platform.


    4.1.3 Dies (designed as per user’s requirement)

    Composite die for forming, hole punching, bending and shearing is designed as per user’s requirement. The head of radiating fin No.2 and bottom of radiating fin No.1 are processed by this die at the same time, the gap to connect with oil pipe will also be punched at that time. And these two fins will be separated by shearing unit.


    4.1.5 Hydraulic System

    Hydraulic system is a standard design, it can work with both single part and whole machine. And all of above compose the closed cycle system. Hydraulic system have full running condition after delivery. All the necessary control, regulating device and oil tank are included.


    4.1.6 Electrical System

    Electrical system consists of separate operating console, buttons, indicator lights, touch screen installed on the panel of operating console.

    The whole working process can be displayed on the touch screen dynamically. And the runtime, quantity of finished sheet, total runtime also will be showing on it.

    Air switch, contactor, power switch, PLC and frequency convertor are assembled on the operating console.

    We select imported parts for colored touch screen for human-machine interface, PLC and frequency controller. All above parts are the key components for the automatic control system. Touch screen has function for parameter input, production operations, dynamic display, it makes the production process clearly.


    4.2 SHEET COMBINING AND TURNING DEVICE

    Sheet combining and turning device is controlled automatically, it have two roller tables. The first radiator fin fed by roll forming machine will be transported to roller table No.1 and overturn 180 degree to roller table No.2. The second radiator fin fed by roll forming machine will be transported to roller table No.1 and pushed to roller table No.2, to the upside of the first fin to finish combining. The operate console is mounted independently. The device can run automatically, also can be handled by manual. Then the two fins will be fed to the transmission rack in front of the multiple spot welding unit.


    4.3 AUTOMATIC WELDING UNIT

    3.3.1 Multiple Spot Welding Unit

    Consists: Single-row 6 spot Multiple Spot Welding Unit, Positioning mechanism, servo tracking welding unit for radiator tail, Special cooling water device.

    This unit is special single-row 6 spot welding machine. It means 6 point can be welded at the same time. The starting signal of the first row welding point is controlled by the first proximity switch of the transmission rack.

    The operate console is independent with touch panel for operation easily. All operation buttons are installed on the console.

    It have auto and manual two modes, the radiator can be controlled to move forward and backward two direction.

    The welding efficiency is 35 pairs per hour. Adjustable range of transverse distance between each two spot of multiple spot welding machine is 50~75mm, it is convenient for adjusting.

    Lower electrode adopt holistic pneumatic floating structure, it can rise up to the same level with the face of weld when welding. There will be a certain distance between the lower electrode and the sheet when the lower electrode lift down, it is convenient for the sheet to move.

    The whole lower electrode is installed on a tapered wedge sliding board. When the electrode tip wore, it can be lifted up by shaking the hand wheel to make it the same level with the initial electrode height.

    The special cooling water system can ensure the cooling effect of the spot welding unit.


    4.3.2 Long side Seam Welding Unit

    This unit is consisted of two sets of seam welding machine, positioning mechanism and special cooling water unit. The distance between the welding wheels of the seam welding machines on the two side is 505mm, that is the central position of the two seams of the radiator fin. One of the welding machines is adjustable,

    The operate console is independent with touch panel for operation easily. All operation buttons are installed on the console.

    Two sets of seam welding device are bilateral symmetry. One of them can adjust the welding width according to the width of the sheet to satisfy the welding requirement of the sheet.

    It have auto and manual two mode, the radiator can be controlled to move forward and backward two direction.

    The cooling water system is Inner recycle water cooling system, and with water-cooling protection device, equipped with the transparent water-collector, easy to monitor.


    4.4 Long side Roll shearing unit:

    Radiator positioning: it use central-positioning mode, which can ensure the center line of two end is aligned.

    Roll shearing and leveling trimming machine is use for cutting the extra materials on the two sides of the radiator fin, then leveling the fin and remove the burrs on the two sides of fin to make it completely.

    The operate console is independent with touch panel for operation easily. All operation buttons are installed on the console.

    It have auto and manual two mode, the radiator can be controlled to move forward and backward two direction.

    It is easy to adjust the shearing width, can meet the 535mm, 520mm,480mm and 310mm width radiator shearing. The roll shearing unit equips with scrap collector device.

    It consists of Roll shearing unit, shearing cutter (2 sets), scrap collector and positioning mechanism.


    4.5 End Stamping & Punching Unit

    It use Oil-pressing machine to punch and cut two pieces one time, it can prolong the working time of cutter. The end cutter is mainly use for cutting the extra materials on the ends of the radiator fin to make the surface completely.

    Radiator positioning: it use central-positioning mode

    The operate console is independent with touch panel for operation easily. All operation buttons are installed on the console.

    It have auto and manual two mode, the radiator can be controlled to move forward and backward two direction.

    It consists of 1 set End stamping & Punching unit and 4 sets of punch cutters (8 pieces).


    4.6 End Stamping Welding Unit.

    It use 4 sets of Argon arc welding unit (2 sets/one side), which are installed on the required position back-to-back.

    Radiator positioning: it use central-positioning mode

    The operate console is independent with touch panel for operation easily. All operation buttons are installed on the console.

    It have auto and manual two mode, the radiator can be controlled to move forward and backward two direction.

    It has the device to press and fasten the edge of radiator end, which will be welded soon.

    The Argon arc welding units are installed on the guide rail, and driven by the step motor and lead screw conveying system.

    It consists of 4 sets of Argon arc welding unit and 4 sets of conveyer mechanism.


    4.7 Transmission Guide rail System

    The transmission guide rail is installed and used on the every machine or unit of complete line. Form roll forming, multiple spot welding, seam welding Cutting, end stamping welding etc. It make the radiator transport more easy and convenient.

    Several roller wheels are mounted on the two sides of the transmission rack to support the sheet, roller wheels are connected with chain wheel and chain wheel.

    On the two sides of the transmission rack, several side wheels are equipped to match with roller wheels to make the sheet feed according to the adjusted setting.

    This transmission rack is mainly used for transporting the sheet, and the space between each two sheets can be adjusted accordingly. The range is approx. 310~540mm.


    5. The main component of the line

    5.1 Roll Pressing & Forming Unit

    No.NameSupplier
    1Loading trolley
    2De-coiler
    3InverterMitsubishi, Japan
    4PLCSiemens
    5Touch PanelSiemens

    5.2 Formed Sheet Combining and Turning Unit

    No.NameSupplier
    1AC motorFamous brand, China
    2Servo MotorYaskawa, Japan
    3Touch PanelSiemens
    4Pneumatic componentSMC
    5Main Electrical componentSchneider

    5.3 Multiple spot welding unit

    No.NameSupplier
    1PLCSiemens
    2Touch PanelSiemens
    3Main LV electrical componentSchneider, Germany
    4Pneumatic componentSMC
    5Cooling water unitFamous brand, China

    5.4 Long side Seam welding unit

    No.NameSupplier
    1PLCSiemens
    2Touch PanelSiemens
    3Main LV electrical component

    Schneider, Germany

    Or Omron

    4Pneumatic componentSMC
    5Cooling water unitFamous brand, China
    6Servo MotorYaskawa, Japan

    5.5 Long side Roll Shearing unit

    No.NameSupplier
    1AC motor, InverterFamous brand, China
    2Speed reducerFamous brand, China
    3Pneumatic componentSMC

    5.6 End Stamping & Punching Unit

    No.NameSupplier
    1Punching Cutter
    2Main LV electrical componentSchneider, Germany
    3Hydraulic station

    5.7 Argon arc welding unit for End Stamping Welding

    No.NameSupplier
    1PLCSiemens
    2Touch PanelSiemens
    3Main LV electrical component

    Schneider, Germany

    Or Omron

    4Pneumatic componentSMC

    5.8 Transmission Guide rail mechanism

    No.NameSupplier
    1AC motor, InverterChina
    2Speed reducerChina
    3Main LV electrical componentSchneider, Germany
    4Pneumatic componentSMC
    5SensorOmron, Japan

    5.9 CNC Hole punching machine for header pipe

    No.NameSupplier
    1PLCSiemens
    2Touch PanelSiemens

    6. REQUIREMENTS

    - Cooling water: flow rate of cooling water ≥ 50L/min, water temperature: 5-30℃.

    - Air pressure: ≥0.55Mpa.

    - Relative humidity: ≤85%.

    - Special requirements: None.


    7. Spares

    Require for 5‐Year Expanded Spare Parts Kit. This kit includes a collection of various parts, which covers the most common replacement requirements in an average 5‐year period.

    Spare Part list:

    No.NameBe used forQTY
    1Springtruncation mold4
    2Electrode tip(Multipoint weld)multipoint welding unit24
    3Feeding hook for formed sheet(including chain)formed sheet and turning device10
    4Electrode wheel(welding wheel)long side seam welding unit2
    5Trimming cutter of electrode wheelweld wheel trimming2
    6Tungsten electrodeargon arc welding for short side4
    7Enamel mouthargon arc welding for short side10
    8Rolling cutterroller shearing machine4
    9O type sealing ringbetween long side seam welding head and welding wheel4
    10Skeleton sealing ringbetween long side seam welding head's shaft and shell4
    11Bearing 32007,32008each 5
    12Conduction oillong side welding head1000ml
    Air pipe connector(commonφ8,φ10)whole gas circuiteach 10
    Air pipe(common φ10,φ8)whole gas circuiteach 20m
    13Seals for Roller force CylinderRoll pressing and forming machine4 sets
    14Electrode capMulti-spot welding unit24 pcs
    15Seam welding wheelLong-side seam welding unit2 pcs
    16Trim bladeLong-side seam welding unit2 pcs
    17Driving wheelLong-side seam welding unit2 pcs

    8. Documentation

    - Schematics for electrical, hydraulic, and pneumatic circuits

    - Machine outline drawings with parts identification for location

    - Operating and maintenance instructions

    - Control software

    9. Acceptance Testing, Training, and Commissioning

    Acceptance Testing and training at manufacturer location is included in the bidding price.


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