Rail Bound Forging Manipulator (5-120Ton) for Metal Material Forging

• After-sales Service: Overseas Services
• Warranty: 12 Months
• Structure: Frame
• Type: Rail Type
• Drive: Full Hydrauliuc
• Function: Workpiece Holding
• Model NO.: JN
• Transport Package: as Required
• Specification: CE
• Origin: China
• Production Capacity: 30 Set Per Year

Product Description

1. Specification of Structure
 Forging manipulator is adopted with rail frame overall structure, with welding components for main structure. Is mainly consist of gantry & its walking construction, clamp tongs structure, clamp rotation device, clamp bracket lifting, tilting structure, clamp bracket side shift structure, clamp bracket sway structure, buffering structure, hydraulic system, operation system, electrical & control system, Lubrication System and so on.
1.1 Gantry & Walking System
Is consist of right/left side boards, boards connection mechanism, wheel unit, hydraulic motor and so on.
Gantry walking is adopted with mechanical transmission driving mode, wheel mechanism, transmission chain and so on, with flat and double wheels rims.  
Overall structure is adopted with integral panel build construction, the main frame is consist of side board and intermediate connection mechanism.
 1.2. Clamp Tongs Fixture Mechanism
Is consist of clamp joint, clamp arms, clamp tongs, clamp cylinder mechanism and so on. Firmly connected between clamp die and clamp arms also being easily dismantled.
1.3. Clamp Tongs Rotation Mechanism
 Is consist of clamp body, hollow shaft, clamp tongs rotation gears unit, rotation motor. Rotating clamp is adopted with low speed motor at maximum torque to drive hollow shaft rotating, setting balance protection loop inside hydraulic system return circuit to insure halt clamp tongs at any positions.
1.4. clamp bracket elevating & Tilting mechanism
Clamp bracket elevating system has two functions: parallel lifted and clamp tongs pitched. Clamp bar lifted is drive with hydraulic cylinder, leveled lifted and clamp tilted working as two independent controlling system can be operated separately at the same time.
 Parallel lifter mechanism is consist of front boom, lateral beam, front rocking arm, lifting parallel
hydraulic cylinder, mechanism connection rod, back rocking arm, pitch cylinder and so on. Which can drive four connection rod mechanism to push forward clamp bracket lifted parallel. Through mechanical connection rod it can form four paralleled connection rod mechanism, the applied force turn into internal forces. Lifting cylinder can drive the rocking arm directly but rocking spindle does not take any torque.      
     Clamp pitching mechanism is consisting of pitching cylinder, parallel lifting fixture. The extension of Pitching cylinder can drive the back lifting point of clamp bracket to lift up and down, to make clamp tongs tilt up and down.
1.5. Clamp bracket punching press mechanism
Included vertical punching mechanism and parallel punching mechanism, both are hydraulic drive punched.
Vertical punching mechanism is consist of parallel lifting cylinder, hydraulic accumulator, overloaded protective valve and so on.
      Parallel punching mechanism is consisting of punching cylinder. Parallel punching is double actions punching that can give punch to both front and back of clamp
1.6. Side Step, Sway mechanism
It is consist of side step cylinder, side step cross beam.
Side step cross beam working as a whole with side step cylinder, which can achieve side step through the beam moved from front and back rocking arms to drive boom and clamp bracket.
With side step punching mechanism to absorb lashes produced from side step, it effectively prevent clamp bracket to cross sway in the process of forging.   
1.7. Hydraulic controlling system
Hydraulic controlling system is consist of oil cylinder, oil motor, oil pump generator, controlled valve unit, piping, oil tank, punching mechanism and so on. With the help of driving oil cylinder and oil motor to push performing fixture complete any procession actions  
1.7.1 oil pump generator.
Hydraulic controlling system is consisting of three sets as follow: 2 sets of A2FO107 and one set of 10YCY, which can output power oil separately, also output power oil together.  
1.7.2 Controlling valve.
This hydraulic system is adopted with two-port Cartridge Valves, Solenoid valve and proportion valve to control hydraulic procession organization. Clamp tongs rotation, clamp bracket lifting and ratio of gantry walking are controlled by proportion valve to achieve linkage with hydraulic press.  
1.7.3 oil tank piping system
This hydraulic control system main oil tank is located on gantry body, with filter inside fuel tank to separate oil return area from oil absorbing area. equipped with hydraulic cooling filter system. Fuel tank steel welded after the treatment of chemical conversion. Oil pump generator are arranged onto the gantry with parts of control valves and water cooler put upon the oil tank. Due to poor forging workshop environment, oil pump generator, oil tank, electrical cabinet are specially dust-proof designed.
1.7.4 Because of large hydraulic shocks within hydraulic Forging manipulator, all hydraulic system piping joints are connected with special flange, also added with shocks protective card according to requirement, well distributed pipeline to deduce energy lost and prevent linkage according to technical characters.
1.7.5 with oil temperature and oil level indicators set inside oil tank. Oil need to be added into tank when oil level is lower till it start to work normally, so that hydraulic press can be put into operation.
1.7.6 Cooling water will be added when oil temperature become higher to get oil cooled.
1.8, Electrical control system
1.8.1 Hydraulic press use three phase four wire system, three phase power supply is 380V, 50HZ: control circuit is 220V; pilot-operated solenoid valve power supply is 220V. Set with special electrical control cabinet, inside which are installed transmission electric elements, just like power switch, air switch, A/C contactor, control transformers, power linkage protection and so on. The flood light and Ventilation facilities also are set inside the cabinet; the cabinets are put onto the floor in workshop.  
1.8.2 The main control system use Siemens PLC programmable controller. Operation method is divided into main frame handle operation or to operate it with combination of 1600T hydraulic press. Through switch to change over.
1.8.3 Main frame handle operation is integrated with hydraulic press working table, all kinds of press bottoms, operation levels and brake switch are installed on the working tables to make it working conveniently, the corresponding actions will be generated after push the levels and switch.
1.8.4 Using remote distance to control, PIC control cabinet as main station, through PROFIBUS-DP data bus to get connection with communication and main frame control system to deduce wiring harness.
   1.8.5 Clamp tongs capacity control used pressure sensors, digital display control: measurement and display precision is half point Mpa
   1.8.6 Gantry location used position moving sensors, digital display and control: measurement and precision display is one mm.
1.8.7 clamp tongs rotation angel control use rotating encoders, digital display and control: measurement and precision display is one degree.
1.8.8 clamp bar lifting, clamp bar tilting, clamp parallel punching used displacement sensors to detect position.
   1.9 lubrication mechanism: It use power automatic centralized lubrication system to control lubrication pumps running time and resting time.
      2. Safety system:
2.1 Each part of hydraulic system are set with safety valves overloaded protected when system over pressured.
2.2 Relevant parts of equipment are set with security platform, fences, and escalators, to make sure easy maintenance  
2.3 Set with filter plug, oil level indicator, oil temperature and many other failure indicators.

Forging manipulator
All-hydraulic driving
Rail-bound movement
Carrying capacity: 1-120t
Tongs Center Height:min780-1000mm       max 1500-2500mm
Gauge:2400-4500mm
Travelling speed:21-32m/min
Tongs rotation speed:8~20 r/min
Working oil pressure:10-20Mpa
Total Power:89-220KW
Length:7380-10000mm
Width:3400-5200 mm
Height:3300-4390 mm
Linked with press in the work
Siemens PLC

CAPACITY (T)		5	8	10	15	20	25	30	40	50
MAX MOMENT(T.M)		10	15	25	30	40	45	60	70	90
GRIP OPENING (mm)	min.	150	180	180	200	200	200	200	200	200
-MAX.  ROUND	max.	800	1000	1000	1200	1570	1650	1650	1800	1900
TONGS CENTER HEIGHT (mm)	min.	780	800	800	880	900	950	950	1000	1000
	max.	1500	1600	1800	1880	1900	2300	2300	2500	2500
HORIZONTAL SIDE SHIFT OF TONGS (mm)		2140	2200	2300	2600	2800	2850	2850	2950	3150
GAUGE (mm)		2400	2400	3200	3200	3500	3500	4000	4000	4500
TRAVELLING SPEED m/min		32	32	32	26	26	26	26	21	21
TONGS ROTATION SPEED r/min		10~20	10~20	10~15	10	10	8	8	5~8	8
WORKING OIL PRESSURE (Mpa)		10	10	16	16	16	16	16	16	20
TOTAL POWER (Kw)		89	112	112	141	148	166	202	220	220
EXTERNALITY SIZE (mm)	(L)	7380	8000	8500	8700	9000	9000	9500	9800	10000
	(W)	3400	3470	3980	3980	4200	4250	4560	4600	5200
	(H)	3300	3300	3500	3500	3900	4100	4100	4200	4390