One-stop Bending Solutions For Wires, Tubes And Pipes
One-stop Bending Solutions For Wires, Tubes And Pipes
As a high-precision automated device, the fully automatic pipe bending machine, while improving bending efficiency, also presents specific operational risks. Operators must strictly adhere to safety operating procedures and be proficient in using the equipment to fully leverage its advantages and avoid accidents. The following details the key points of safe operation from three dimensions: pre-operation preparation, core operating procedures, and hazardous area protection.
I. Preparations before operating a fully automatic pipe bending machine
A comprehensive check of the equipment status, environment, and parameters must be completed to ensure that the equipment is fault-free, the environment is free of potential hazards, and the parameters meet the operational requirements. Specific details are as follows:
1. Equipment Status and Lubrication Inspection
• Oil Level and Leakage Inspection: Check if the oil level in the tank reaches the oil level mark (if below the mark, add the same type of hydraulic oil; refer to the equipment manual for recommended models). Simultaneously check the hydraulic system pipelines, joints, and cylinders for any signs of leakage. If leakage is found, stop the machine for repair; do not operate with a leak.
• Motor Rotation Confirmation: After initial startup or power supply change, briefly start the motor to confirm the rotation direction (refer to the “Motor Rotation Mark” on the equipment). If the rotation is reversed, adjust the power phase sequence to prevent the oil pump from reversing and causing damage.
• Lubrication Replenishment: Add special lubricating oil (chain oil for chains, lithium-based grease for gears) to sliding/rotating parts such as chains, sliders, and transmission gears according to the equipment lubrication chart. Do not add oil to the angle encoder.
• Abnormal Noise Troubleshooting: After startup, run the machine unloaded for 3-5 minutes, listening for abnormal noises from the oil pump and motor (such as a “humming” overload sound or a “clicking” jamming sound). If any abnormality is detected, stop the machine immediately for inspection.
2. Electrical Safety Inspection
• Grounding Verification: Confirm that the machine tool’s grounding wire is a copper flexible wire no less than 4mm², with a grounding resistance ≤4Ω. Do not disconnect the grounding device during operation.
• Power Supply Compliance: Check that the connected power supply voltage meets the equipment’s rated range. Do not connect voltages outside the range.
• Electrical Component Protection: Check for impact marks from hard objects on precision components such as proximity switches and encoders. If the casing is damaged, replace it before use. The electrical box must be placed in a well-ventilated area. Do not open the electrical box in dusty or corrosive gas environments.
• Prohibited Operations: Do not plug or unplug electrical connectors while the power is on. Do not use a megohmmeter to test the control circuit (this may damage the PLC, sensors, etc.). Do not add or modify PC input/output terminals without authorization.
3. Die and Parameter Adjustment
• Die Installation and Calibration:
a. Select the matching die head according to the outer diameter of the pipe to be bent, place it on the plunger, ensuring that the corresponding grooves of the two rollers face the die head, insert it into the corresponding size perforated plate hole, and then cover it with the perforated plate;
b. Adjust die alignment: Adjust the clamping block using bolts to align the die with the center of the clamping block; adjust the position of the pusher block to ensure that the pusher block is aligned with the center of the die; loosen the mandrel bracket bolts, align the mandrel with the die center, and then tighten the bolts to avoid pipe deformation or equipment jamming due to alignment deviation;
• Pressure Setting: Adjust the system pressure using the electromagnetic overflow valve. The pressure must meet the operational requirements and not exceed 12.5 MPa (refer to the pipe material and bending angle parameter table for specific pressure). Overpressure operation is prohibited.
1. Equipment Start-up and Connection
a. Tighten the drain screw on the electric oil pump. Pull the movable part of the quick connector at the end of the high-pressure oil pipe backward and align it with the working cylinder connector, tightening it (a “click” sound indicates proper connection). Do not start the oil pump if the oil pipe is not properly connected.
b. Screw the working cylinder into the internal thread of the square stop block, ensuring the wheel on the rear support of the cylinder faces downward to ensure stable cylinder operation.
c. Press the equipment power switch and observe whether the indicator lights on the control panel are normal (power light on, fault light off is normal). If the fault light is on, check the fault code before starting.
2. Pipe Clamping and Bending
a. Insert the pipe to be bent into the groove of the mold and roller, ensuring one end of the pipe is firmly against the positioning block. Do not place the pipe at an angle (an angle may cause deviation in the bending angle or the pipe to pop out);
b. Switch the equipment to “Automatic” or “Manual” mode (automatic mode for batch operations, manual mode for single-time debugging). In manual mode, first perform a jog test to check if the clamping block and pusher block are functioning correctly before proceeding with the bending process;
c. Start the bending program and observe the pipe bending process. If pipe deformation or abnormal noise is observed, immediately press the emergency stop button. Do not force continued operation;
d. After bending is complete, loosen the drain screw on the electric oil pump. The plunger will automatically reset. Remove the pipe only after the plunger has fully reset.
3. Shutdown and Finishing
a. After each operation, turn off the equipment power and disconnect the main distribution box switch;
b. Remove the high-pressure oil pipe (first loosen the vent screw to release pressure, then disconnect the quick connector), clean the metal debris from the die head and tube sheet, and apply anti-rust oil;
c. Tidy up the work site, classify and store the pipes and tools, and fill in the equipment operation record (record the number of bends, equipment status, and whether there are any abnormalities).
III. Hazardous Areas and Protective Measures of Fully Automatic Pipe Bending Machines
Fully automatic pipe bending machines have three high-risk areas that require special protection, as follows:
| Dangerous Area | Risk Type | Protective measures |
| Between the bent arm and the fixed arm | Pinch injuries, crush injuries | 1. Install infrared protective light curtains; the equipment will automatically stop when a human body enters the area. 2. Do not manually adjust the position of the pipes while the equipment is running. 3. Operators must wear protective gloves and should not wear loose clothing (to avoid clothing getting caught). |
| Bending Angle Selector Area | Mechanical impact, component detachment | 1. The angle selector must be equipped with a protective cover; operation without the cover is prohibited. 2. The machine must be stopped when adjusting the angle; parameters must not be modified while the machine is running. 3. Regularly check whether the connecting bolts of the angle selector are loose; tighten them immediately if they are. |
| Pipe loading and unloading area in front of the machine head | Pipe ejection, swirling impact | 1. The machine must be stopped when loading and unloading pipes; inserting or pulling pipes while the equipment is running is prohibited. 2. A guardrail at least 1.2 meters high must be installed in front of the machine head; crossing the guardrail to operate is prohibited. 3. Before bending the pipe, ensure that the clamping force is sufficient to prevent the pipe from popping out during bending. |
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Innovative forming technology of fully automatic pipe bending machine
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