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Perfect Manufacturer in China of CNC Header Pipe Drilling Machine Djx3512 for Pressure Vessel Boiler1
Machine Tools, Drilling Machine, Pipe Drilling Machine, Header Pipe Drilling Machine
Jinan Safety United Technology and Trade Co., Ltd.
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Product Description CNC Header Pipe Drilling Machine DJX3512 1.Application:This machine is primarily used for drilling header-type tube hole in the boiler industry. It can automatically complete drilling, boring, spot facing, milling, and other processes in one operation. Using this machine the manual scribing, marking, and other auxiliary tasks needn't, significantly improving the precision and efficiency of workpiece processing and shortening the production preparation cycle.2.Overall description of the machineThe drilling and milling machine is a flexible CNC machine with complete functions, advanced system, and high degree of automation. It meets the needs of various batch production and realizes civilized automated production, which is in line with the trend of intelligent development of modern factories.This machine has a square type gantry and a single drilling and milling power head structure, with complete and reliable safety protection, and a beautiful appearance. The equipment selection is reasonable, the manufacturing is excellent, the performance is outstanding, the accuracy is stable, and it has good static, dynamic, and thermal stiffness, suitable for long-term, continuous, and high load processing; The operating interface is simple, intuitive, and smooth. The whole machine has stable performance, reliable operation, and easy maintenance. Design and manufacture in compliance with national safety and environmental standards.3. The Main Structure and Characteristics: For ease description, the specific definitions of each operation axis and direction are as follows: the gantry moves along the length direction (longitudinal) of the header as the X-axis (X1 axis and X2 axis), the indexing head moves along the length direction (longitudinal) of the header (or machine tool) as the X3 axis, the drilling and milling power head moves along the span direction (transverse) of the gantry crossbeam as the Y-axis, the XY axis is perpendicular to each other in the horizontal plane, the vertical movement direction of the drilling and milling power head is the Z-axis, the Z-axis is perpendicular to the XY horizontal plane, the indexing head chuck rotates as the A-axis, the A-axis rotation axis is parallel to the X-axis, and the spindle rotation is the SP axis. The operator standing in the operating room of the host facing the workpiece is considered to be in front, and vice versa, and the front to back direction is also the Y-axis transverse direction; The left and right sides are the length direction of the container (or machine tool) (X-axis longitudinal direction), and the indexing head chuck clamps the workpiece with the head end located on the left side of the host and the workpiece tail end located on the right side of the host.The machine mainly consists of a bed body, CNC dividing head, gantry and sliding plate, drilling and milling power head, workpiece support and clamping device, pressing device, header length and tee end face alignment device, header bending measurement system, cooling system, chip removal, lubrication system, pneumatic hydraulic system, control system, as well as tool magazine, tooling and cutting tools. Its structure and characteristics are as follows:3.1 The bed, gantry, slide saddle, and power head slide pillow are widely made of high-quality castings, which have good seismic performance and are conducive to maintaining the stability of mechanical performance.The bed frame is the basic component of the machine tool, which is made up of multiple sections of bed frames that are connected together. The bed frame is treated with overall thermal aging to relieve stress and has good rigidity and stability Two bed frames are arranged in parallel and vertically, with two high load-bearing linear rolling guide pairs arranged on each bed frame for guidance. There is a large modulus rack and a set of grating rulers for positioning and detection in between.One set of longitudinal sliding tables is installed on the bed guide rail pair to support the gantry. Each sliding table is equipped with an AC servo motor that drives the clearance reduction helical gear to move longitudinally (X-axis) on the meshing rack through a precision reducer. The double-sided motors synchronously drive the sliding table (gantry) to move longitudinally (X1 axis and X2 axis). The X-axis adopts a grating ruler closed-loop detection, with high positioning accuracy.The machine tool reserves a gantry parking space, allowing for vertical lifting of 18m workpieces.The gantry column is installed on top of two bed slide tables, and the single gantry frame is an integral structure that adopts integral thermal aging stress relief treatment, with good rigidity and stability. 3.2 The gantry adopts a double door square type gantry structure, which has sufficient rigidity and smooth operation, which is conducive to ensuring the machining quality of workpieces and the service life of cutting tools.The longitudinal movement of the gantry (X axis) is guided by four straight rolling rails (two rails on each side) fixed on the bed, providing flexible movement. The drive adopts two AC servo motors, which are synchronized on both sides through precision reducers and large modulus anti backlash helical gear and rack pairs. The gear and rack have anti backlash mechanisms.The cross-section of the gantry crossbeam is L-shaped, and the guide rails are installed on opposite sides of the upper and front sides. Each crossbeam is equipped with a precision roller guide pair on the upper and front sides of the inner side. The gantry has a reasonable load-bearing structure, good shock absorption effect, and stable performance.3.3 The Y-axis skateboard (saddle) is installed on the crossbeam and serves as the mounting base for the drilling and milling power head slider.Two horizontal beams are installed in parallel and symmetrically arranged, with two high load-bearing linear rolling guide pairs arranged horizontally on the inner side of each beam for Y-axis guidance. The four sets of guide pairs on the two horizontal beams are equipped with a set of horizontally moving sliding saddles for installing the power head slider (Z-axis), which are driven by a servo motor through a precision planetary reducer to drive the Y-axis screw pair to move laterally.3.4 The drilling feed is controlled by servo, and the feed stroke can be automatically memorized. Not only is the drilling efficiency high, but the accuracy is also high. When the drill bit quickly approaches the workpiece, it automatically switches to work in, and rapid feed automatically switches to work in. After the workpiece is drilled through, the drill bit quickly retracts. It can greatly save auxiliary time, so the machining efficiency of this machine is high;The power head also has the functions of graded feed and automatic chip breaking. The blind hole depth and chamfer size can be processed arbitrarily, and the consistency during countersunking is good3.5 The drilling and milling power head adopts the BT50 precision internally cooled spindle produced by a professional manufacturer. The spindle taper hole has a butterfly spring automatic tool pulling mechanism, hydraulic loosening tool, and automatic blowing to clean the spindle inner hole. It has tool tightening status monitoring and safety interlock protection, making replacement safe and easy.3.6 The workpiece achieves rotational indexing through precision rotary bearings on the CNC indexing head. The CNC dividing head is installed on the longitudinal sliding plate at the left end of the machine base, and the X3 axis servo motor drives the screw pair to drive the sliding plate to move longitudinally, with accurate positioning and convenient processing and loading and unloading of the collection box.The motor drives the ball screw pair lifting chuck through the reducer, and moves up and down by 200mm stroke. The center position of the chuck can be adjusted vertically and can freely float up and down for buffering, facilitating the clamping of workpieces of different diameters. The chuck can also float up and down with the change of the position of the header end, reducing the damage caused to the chuck by the additional force generated during the rotation of the header.3.7 The workpiece support is mainly used for the support and clamping of the collection box, evenly distributed on the track. It is driven by a hydraulic motor installed on the support slide to rotate the gears and move longitudinally (X-axis) on the meshing bed rack. The moving speed is adjustable for easy support arrangement.3.8 The machine is equipped with a pressing device, which is used in conjunction with the workpiece support to securely fix the header and prevent vibration during the cutting process.3.9 Non contact laser measurement sensors and contact mechanical measurement devices are installed on the gantry and power head of the machine tool, which can achieve the alignment of the tee end face before processing, the measurement of the header length, the measurement of curvature, and the measurement of the deformation of the hole position workpiece during the processing to ensure the accuracy of groove processing. For specific introduction, please refer to the electrical system description later.3.10 There is 16 piece bucket hat style intelligent tool magazine installed behind the gantry, which can achieve fast and accurate automatic tool changing without human intervention, reduce the labor intensity of workers, and achieve civilized and efficient automated production. The tool changing system has high stability and extremely low failure rate. After long-term operation, it can continuously and accurately change tools, avoiding the phenomenon of tool changing or dropping due to factors such as inadequate tool taking devices.3.11 The machine is equipped with two sets of hydraulic systems, one set installed on the gantry, mainly controlling the hydraulic actuators that move with the gantry, such as cutting, weight balancing of the power head, sliding saddle and gantry locking, and material pressing; The other set is installed on the ground and mainly controls other hydraulic actuators, such as workpiece support movement, workpiece support frame lifting and clamping, chuck floating, etc.3.12 The internal and external cooling pumps of the machine tool cooling system work independently, and the internal and external cooling can be supplied separately or simultaneously without the need for manual switching. The sprayed coolant flows back into the coolant tank through the accumulation tank, and the coolant can be recycled. Equipped with a filtering device and a high-pressure water gun to facilitate the cleaning of iron filings from the supporting device.3.13 The stainless steel chain plate chip conveyor is placed under the support base between the two bed frames, and discharge the iron chips into the iron chip box. 3.14 The equipment adopts two sets of centralized automatic lubrication systems, one set installed on the gantry, mainly lubricating the points that move with the gantry, such as X1, X2, Y, Z-axis guide rail pairs and screw pairs, guide rods, etc; Another set is installed on the dividing head, mainly to lubricate the nearest points of the dividing head, such as the rotary support ring gear, X3 axis, chuck lifting guide rail pair, and screw pair. 3.15 The electrical system is based on the Siemens 828D system (control unit PPU290) to control the operation of the machine tool, achieving dynamic monitoring of human-machine dialogue, program programming, storage, and operation; The automatic control of fast forward, work in, fast backward drilling and its auxiliary operations has greatly improved the precision, efficiency and reliability of drilling processing. All CNC axes are controlled by Siemens S120 drive system (including motor), equipped with ALM adjustable power module with AIM interface and Siemens handheld unit as standard; The XY gantry axis adopts Heidenhain grating ruler for full closed-loop detection.The system features an LCD display and a user-friendly interface, with functions such as human-machine dialogue teaching, counting of workpiece processing quantities, error compensation, multi axis interpolation, power-off protection and power-off memory, real-time dynamic detection and processing of tool breakage, tool life management, automatic alarm, real-time monitoring, remote diagnosis, etc. It is also equipped with CF card interface, Ethernet interface, and USB interface.The entire drilling process has achieved computer numerical control monitoring and automation control.Main technical parameters:ItemDescriptionParameterSize of header tubeMaterials of header tubeCarbon steel (20G, SA-106C, etc.)Alloy steel (15CrMoG, 12Cr1MoVG, SA-335P91, SA-335P92, etc.) Stainless steel material (SA-312TP321H, 12Cr18Ni9Ti, 316L, etc.) Outer dia. Of header tubeΦ100~φ350mmThe thickness of header tube5~60mmThe length of the header tube2~15mWeight of header tube≤20tDrilling diameterφ3~φ50mmMax.rotation dia. Of header tubeΦ380mmProcessing method and accuracyProcessing methodUsing specialized clamp type cutting tools (hard alloy blades), drill through the hole first, then change the tool to process the bowl shaped hole, or use a socket drill for processing.Accuracy of spacing between any two vertically adjacent holes±0.1mmDeviation of center distance between any adjacent pipe holes in the circumferential direction±0.5mmAccuracy of spacing between any two vertical holes±0.5mmDeviation of spindle feed rate(Deviation in groove depth)±0.3mmPipe hole roundness≤0.05mmSurface roughness of drilling holes≤6.3μmDimensional accuracy of drilling holesIT11~IT12CNC dividing headQuantity1Chuck formSelf centering hydraulic chuckSelf centering four jaw chuck diameterφ550mmCenter high adjustable itinerary/mode±100mm/JogVertical moving motor power2.2 kWTravel along the X-axis direction≥1000mmRotary motor power≥10kWRotary speed0~4r/min(with CNC)Division positioning accuracy2.5′Repetitive positioning accuracy of division1.5′Vertical feed rate modeJogHorizontal feed rate modeJogDrilling head and vertical slide table Quantity1Tipper of spindleBT50Power of spindle motor≥37kWMax.torque of the spindle800NmSpeed of spindle30~3000 r/minStroke of axis-Z≥400mm()Stroke of axis- Y≥200mmMax. Speed of aixs- Z5000mm/minPower of axis-Z≥3kWMax.speed on direction axis-Y10000mm/minMotor power on axis-Y≥3.1kWAccuracy on axis-Y/Z0.03mm/Total length Repeat accuracy on axis-Y/Z0.02mm/1000mmDriving wayServomotor +ball screwGantry on axis-XQuan. Of gantry1Driving method+Max.stroke on axis-X for gantry≥15mMax.speed on axis-X10000mm/minMotor power on axis-X4.2kW×2Accuracy on axis-X0.15mm/Repeat accuracy on axis-X0.01mm/1000mm;0.08mm/Total lengthSupportLift support4pcsFixed clamping support7pcsFloating support3pcsManual lifting support6pcsLift stroke400mMTools magazineType/quan.bamboo hat/1setTools quantity8Model of tipperBT50CND systemquantity1setModelSiemens 828DQuantity of CNC axis4+1(4pcs feeding axis,1pcs spindle)Hydraulic systemquantity2setsPressure/flow3~7MPa/16.7L/minPower of motor 2.2kWCooling systemInner cooling pressure/Flow5MPa/70L/minPower for inner cooling pump 7.5kwPower for outer cooling pump 0.75kWLubrication systemModeManual+AutomaticAutomatic system2 sets/Oil injection cycle and oil quantity can be digitally programmedChip remove conveyorTypePlate-chainquantity1setPower of motor2.2kWTotal power 120kWDimension(L×W×H)(m)20×6.5×6mWorking input voltageThree-phase four-wire AC380±10%V 50±1HZ Control input voltageAC220±10%V 50±1HZ ,Main component manufacturerNo.NameBrandCountry1Leaner guide wayHIWIN/Taiwan, China2Drilling spindleKenturnTaiwan, China3Ball screwI+F/NEFFGermany4CNC system, servo system, handwheel, DC stabilized power supplySiemens 828DGermany5Servo motorSiemensGermany7X-axis gear rack pair ATLANTA/Germany/Switzerland8Precision dual speed gearboxZF/BFGermany/Italy9Hydraulic valveATOS/Italy/Germany10Oil pumpATOS/Italy/Germany13Electrical component/Germany/France
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