J-series High Quality Hydraulic Stiffener Plate Element Straightening Machine

A. Usage and Application of J20/ J28 Stiffener Plate unit Straightening Machine:

1. Workpieces of Ribbed Plate unit Straightening Machine:

Large Section Beam or Large Section Box Beam:

In the field of Port Machinery and Hoisting Machinery manufacture, there is a kind of important workpieces, which serve as elementary metal structure member of assembly in the integral machine:

1) Cross section height is in the range of 1000 ~1500 mm;

2) Cross section width is in the range of 1500 ~3000 mm;

3) Total length of the workpiece is in the range of 20~ 30m;

To make sure these section BOX Beams to have sufficient integral strength, there are Ribbed Plate Element, or called Stiffener Plate Element, to be fabricated inside the Beams: (Fig.1)

What Is: Please see attached and above picture. A piece of steel plate, on its top surface, with one to three or more pieces of stiffeners or ribs in parallel, to make the plate with sufficient rigidity, for the next step of producing large section beam or large section box beam;

2. Machine Function: The J series Ribbed Plate Element Straightening Machine is for straightening the stiffeners on the plate unit, after these stiffeners being welded onto the plate.

B. Technical View on J20/ J28 Ribbed Plate unit Straightening Machine:

1. Operation Principle of Stiffener Plate Element Straightening Machine:

Please check attached and below photo taken at Wuxi JACK workshop, during machine commissioning: (Fig.2)

1) Overall Theory: The machine adopts working way of workpiece passing thru its mechanical main frame, and got straightened at the same time. This is similar to H Beam Straightening Machine, and Angle Steel Straightening Machine;

2) Each of the straightening unit is the combination of two pairs of top straightening rollers, with one piece of bottom straightening roller. The top straightening rollers move downward, and the bottom straightening roller just revolve;

3) During work, stiffener plate moves thru the clearance between the top and bottom rollers, and got straightened at the same time. See below: (Fig.3)

4) Straightening Unit Quantity: There are three groups of straightening units installed into one set of the machine. So, up to three pieces of stiffener plate / rib plate on the plate unit can be straightened simultaneously.

2. Main Units of Rib Plate unit Straightening Machine:

This machine is mainly composed of:

1) Stationary BOX gantry frame main body;

2) 3 sets of straightening units;

3) 2 pieces of supporting rollers;

4) Input and output conveyor roller tables;

5) Hydraulic system;

6) Electric control system;

3. Drive Way of Stiffener Plate Element Straightening Machine:

1) The main operation step: The up and down vertical movement of top straightening rollers/ Supporting rollers are driven with hydraulic system, providing sufficient heavy driving force;

2) Supplementary Motions: Transverse movement of Top Straightening rollers/ Revolve of bottom straightening rollers/ Conveyor roller rotation for sending workpiece, are all driven with different motor reducers;

4. Overall Layout of Ribbed Plate Element Straightening Machine:

Please check attached and below photo: (Fig.4)

1) Support Unit: Electric control board and hydraulic pump station are put onto the overhead platform of machine main frame. This is for saving land occupation;

2) Access to the overhead platform is by way of the staircase. The staircase and guardrail of the platform are made from 30*30mm square tubes. The staircase is fit at the lateral side of the gantry frame;

3) The central function unit is assembled inside BOX Beam, on machine base bed. This not only give protection on function unit, but more importantly, avoiding operators approaching rolling units, so as to make sure safe operation on site;

5. Electric Control System of Stiffener Plate Unit Straightening Machine:

1) Composition: Control system of this machine include electric control board and remote operating panel;

2) Brand: All the electric elements of control system are purchased from Chinese or Overseas renowned suppliers, including PLC/ Air breaker/ Contactor/ Relay, etc.;

3) Operation: All the buttons/ toggle switches on controlling working actions are integrated into the remote panel: (Fig.5)

4) Straightening Velocity: As default design, like all the other types of steel structure straightening machines, such as H Beam/ Angle Steels, the ribbed plate straightening speed here is also constant. Of course, if customer requests, we can provide adjustable straightening speed.

C. Operation on J20/ J28 Rib Plate unit Straightening Machine:

We discuss this in the sequence of working process of the machine.

1. Workpiece Send into Stiffener Plate unit Straightening Machine:

1) The workpiece is feed into main body of gantry frame by way of input conveyor;

2) The supporting rollers mentioned before is for raising the workpiece and putting it onto the bottom straightening roller. Its revolve transmission is engaged with that of the bottom straightening rollers by means of chain sprocket couples;

3) For this purpose, the supporting rollers has vertical stroke of 40mm driven with hydraulic cylinder. When the machine is in straightening, its surface is 20mm lower than that of input conveyor; When workpiece is sent in, it rises and has its surface 20mm higher than that of input conveyor, supporting the workpiece and then lower the workpiece onto the bottom straightening roller;

4) For the easy control of workpiece manipulation with this machine, the front and rear supporting rollers work individually; Their extreme positions of top and bottom are at same level;

2. Straightening Process in Ribbed Plate unit Straightening Machine:

1) Surface of the bottom straightening rollers is 5mm higher than that of conveyor;

2) This means, when this machine is in straightening, both the front and rear supporting rollers and conveyor rollers have its surface height lower than that of the bottom straightening rollers;

3) In this way, the supporting rollers and conveyor rollers will not be affected with straightening process and got protected in the largest degree.

D. Design Reference of J20/ J28 Stiffener Plate Element Straightening Machine:

As the large machinery being applied in Port Machinery/ Shipbuilding, this Stiffener Plate Element Straightening Machine is designed by Wuxi JACK engineering team, strictly conforming to corresponding national standards:

1. JB5226.2《Safety Standard on Mechanical Machinery and Electric units》

2. GB4064  《Guideline on Security of Electric units》

3. GB6988  《Electric Drawing》

4. GB/T1184《Position and Position Tolerance》

5. GB/T1800.3《Limit and Fit》

6. GB4884  《Notation of Insulated Conductor》

7. GB/T3384《General Technical Requirements on Package of Electromechanical Products》

E. Technical Parameters of J20/ J28 Ribbed Plate Element Straightening Machine:

Model Parameter	J20	J28
Stiffener Plate Width	1000 ~ 3000mm
Stiffener Plate Thickness	8~ 20mm	8~ 28mm
Quantity of Straightening Unit	Three sets
Top Straightening Roller Transverse Stroke	4000mm
Min. Span of Top Straightening Roller	700mm
Range of Interval of Stiffeners	225- 700mm
Surface Height of Input and Output Conveyor	600mm
Hydraulic System Rated Pressure	25 MPa
Max. Pressure of Solitary Straightening unit	30 Ton
Specification of Bottom Straightening Roller	High Pressure Oil Cylinder D125/d70-S200
Straightening Speed	6,000 mm/min
Vertical Stroke of Supporting Rollers	40mm
Straightening Roller Motor Power	15.0 kW
Hydraulic Station Power	5.5 kW
Positioning and Detection of Transverse Movement of Straightening Rollers	Zero Position set with Proximity switch; Detected with encoder
Electricity Power Specification	3P AC380V 50Hz (for Chinese market)