The BP-440SS type bolt automatic upsetting machine is equipped with a highly sophisticated clamp system, designed for precision and efficiency in the forging process. The clamp mechanism consists of four main components: the clamp assembly, transmission, lifting system, and external adjustment unit. Additionally, it includes pneumatic elements (such as 11 cylinders and other pneumatic components) and hydraulic parts (including two inverted hydraulic locks and one hydraulic cylinder), along with lubrication systems to ensure smooth operation.
The caliper body is made up of several key parts, including a slide seat, slider, sliding body, swing frame, tilting shaft, and locking hydraulic cylinder. It also features five cam-adjusting locking cylinders, an automatic connecting cylinder, four pneumatic spring cylinders, a zero clamp cylinder, and two hydraulic rotary cylinders. This structure allows the workpiece to be transferred sequentially between the first, second, third, and fourth forging stations. Once all operations are completed, the fifth clamp moves the finished part into the collection bin. The caliper body can rotate freely within a 90° range, and the slider can be detached for easy adjustment and maintenance of the cold heading machine’s clamping system.
The transmission system transfers motion from the crankshaft to a spur gear, which then drives a bevel gear (three groups) and a double cam. This motion is finally delivered to the caliper body and the cam group. A small bevel gear encoder is also integrated to monitor and display the conical movement of the clamp, ensuring precise control.
The lifting system comprises a frequency-controlled motor, speed reducer, worm and worm wheel, base, 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 caliper body, facilitating jaw alignment and repair.
Installation challenges include precise positioning of the lift base and adjustment base relative to the bed body. These components are indirectly connected to the caliper body and must align accurately with the cam group, achieving a three-dimensional position accuracy of ±0.05mm in X, Y, and Z directions.
To adjust the base level, special tooling and inspection devices are used. A self-made inspection sleeve and shaft are installed in the first and fourth female mold positions, while a dial gauge is used to measure horizontal and vertical alignment. Adjustments are made by trimming shims to achieve a tolerance of 0.03mm.
Next, the clamp height is adjusted so that the center of the clamp matches the centers of each station in the female mold, keeping the error within 0.07mm. Four sample rods are created for inspection, placed in each station, and adjusted until the clamps grip the samples within a 0.07mm tolerance.
A 0.48mm thick adjustment plate is placed on the end of the female mold base to create a 0.5mm clearance between the jaws and the mold. After aligning the clamp with the plate, the clamp is lifted and secured to the bed using bolts and pins, ensuring proper positioning before final tightening.
The connection between the caliper body and the clamp is made through a coupling body and bolt, allowing for adjustable and precise alignment. When the caliper body rotates, the coupling separates, but when it returns to the working position, it automatically reconnects, provided the automatic coupling cylinder is properly locked.
After installation and adjustment, the commissioning process involves testing the lift clamp cam, lockers, jaws, automatic coupling bolt, cylinder, and overall positioning of the caliper body. Following trial production, the system proves stable, reliable, and meets all design specifications, earning high satisfaction from users. This machine is well-suited for the market and is expected to play a significant role in the future of automatic cold heading technology.
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FOSHAN CITY KURUI LIGHTING CO.,LTD , https://www.kuruilighting.com