The BP-440SS type bolt automatic upsetting machine is equipped with a highly precise and complex clamp system designed to ensure accurate positioning and smooth operation during the forging process. The clamp mechanism consists of four main components: the clamp assembly, transmission system, lifting unit, and external adjustment mechanism. In addition, it integrates pneumatic and hydraulic systems for enhanced control and performance.
The pneumatic system includes 11 cylinders and various pneumatic components, while the hydraulic part features two inverted hydraulic locks and one hydraulic cylinder, along with lubrication elements. This combination ensures smooth and reliable movement of the clamping jaws throughout the forging cycle.
The clamp body itself is made up of several key parts, including a slide seat, slider, sliding body, swing frame, tilting shaft, and locking hydraulic cylinder. It also incorporates five locking cylinders for cam adjustment, an automatic connecting cylinder, four pneumatic spring cylinders, a zero clamp cylinder, and two hydraulic rotary cylinders. These components work together to move the workpiece between the first, second, third, and fourth forging stations. After the four operations are completed, the workpiece is transferred to the final bin by the fifth clamp. The clamp body can be freely flipped within 90°, and the slider can be detached for easy adjustment and maintenance of the cold heading machine’s clamp system.
The transmission system transfers motion from the crankshaft to a spur gear, which then drives the bevel gear (three sets), double cam, and finally the clamp body and cam group. A small bevel gear encoder is also included to monitor and display the conical motion of the clamp, ensuring precise alignment during operation.
The lifting mechanism comprises a frequency modulation motor, speed reducer, worm and worm wheel, base and rotating body, bracket, three electronic cams, a positioning cylinder, and two stoppers. Its primary function is to enable a 90° flip and rotation of the clamp body, facilitating jaw adjustment and repair.
One of the major challenges in installation is achieving precise positioning of the clamp base and adjustment base, which are indirectly connected to the bed body and must align accurately with the cam group. This requires three-dimensional spatial accuracy in X, Y, and Z directions, with tolerances maintained within 0.05mm.
To achieve this, special tools and inspection devices are used to check horizontal and vertical levels. Inspection sleeves and shafts are installed in the first and fourth steps of the female mold base, while dial gauges are used to measure and adjust the base height to within 0.03mm. The clamp is then adjusted so that its center matches the center of each station, keeping the error below 0.07mm. Sample rods are made for each station to ensure uniform clamping force, with adjustments made to maintain a tolerance of 0.07mm.
The clearance between the jaws and the female mold end is set at 0.5mm. A 0.48mm thick adjustment plate is placed on the mold base, allowing the jaws to close tightly against it. Once aligned, the clamp is lifted, secured with bolts, and locked to the base using a 0.5mm gauge for precision.
The connection between the clamp body and the base involves a connecting body that forms a flexible joint with the coupling body. The coupling screw connects to the coupling shaft and allows for adjustment, with positioning ensured by a sleeve. When the clamp body is raised, the coupling separates automatically, and when it returns to the working position, it re-engages with the help of an automatic coupling cylinder, which must be locked before disengagement.
After installation and adjustment, the commissioning process includes testing the lift clamp cam, lock mechanism, jaws, automatic coupling bolt, coupling cylinder, and overall positioning of the clamp body. Following trial production, the system operates smoothly, reliably meeting all design specifications. Users are highly satisfied with the performance, and the product is well-suited to meet growing market demand in the domestic automatic cold heading machine industry.
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FOSHAN CITY KURUI LIGHTING CO.,LTD , https://www.kuruilighting.com