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Intelligent robot & manipulator

10-100 Tons Full-hydraulic Rail Forging Manipulator

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Product description: The 10T full-hydraulic rail forging manipulator is suitable for producing free forging forgings such as long shafts, disks, rings, thick plates and square billets. It can clamp the workpiece and complete the forging operation with 20MN free forging Hydraulic press, and realize the free forging of ingots (billets) of various materials in hot state, which can fully meet the forging process requirements such as upsetting, drawing, punching, ring expanding and cutting.
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The 10T full-hydraulic rail forging manipulator is suitable for producing free forging forgings such as long shafts, disks, rings, thick plates and square billets. It can clamp the workpiece and complete the forging operation with 20MN free forging Hydraulic press, and realize the free forging of ingots (billets) of various materials in hot state, which can fully meet the forging process requirements such as upsetting, drawing, punching, ring expanding and cutting.

Pic. of Equipment model: DCZY-8-6

Fuction：

a) The 10T full hydraulic rail forging manipulator is driven by full hydraulic pressure, which can realize the single operation of the press on the same stage.

b) Its structural form is designed as an integral wallboard structure, which can clamp forgings to complete eight actions:

lForward/backward of the vehicle body

lClamping/releasing of the jaws

lForward/reverse rotation of the pliers head

lParallel upward/downward movement of the pliers body

lUpward/downward inclination of the pliers head

lLeft/right translation of the pliers body

lLeft/right swing of the pliers body and

lForward/backward movement of the pliers body.

c) The manipulator also has the functions of clamping and maintaining pressure of the pliers head, vertical up and down of the pliers body-horizontal back and forth-left and right rotation buffering; It can also realize the automatic leveling and centering of the pliers body, the accurate positioning of the car body walking and the rotation of the pliers head.

d) The manipulator has the functions of clamp head clamping and pressure maintaining, clamp body buffering (including vertical up and down, horizontal front and back, horizontal left and right), automatic leveling of clamp body and automatic centering of clamp body, and can realize accurate positioning of main actions such as car body walking and clamp head rotation. It can clamp forgings according to the rated clamping tonnage and clamping torque and cooperate with the rapid forging machine to meet the production needs of the rapid forging machine.

e) The rotating torque and clamping torque of the clamp rod can be easily adjusted at the operation console, and the clamp rod has buffering function in the three coordinate axes of X/Y/Z Y/Z. It can realize the free forging of ingots (blanks) of various materials in hot state, fully meet the forging process requirements of upsetting, drawing, punching, ring expanding and cutting required by conventional forging products, and complete the forging operation and production of shafts, cakes, rings, thick plates and square blanks.

f) The manipulator is equipped with advanced detection, sensing elements and auxiliary devices, system fault self-diagnosis system, programmable control and forging.

g) It has a complete monitoring system, which can comprehensively monitor and display the operation displacement, system force and energy parameters, temperature and faults in real time. The device has remote diagnosis function. Remote operation and diagnosis can be realized through the network interface reserved by customers.

h)The manipulator is equipped with a shortcut key for controlling the rotation angle, which can realize the one-key positioning function of 0, 45 and 90, and other angles can be set at will according to the process requirements. The manipulator has the function of automatic compensation of rotation angle to ensure that the cumulative accuracy of multiple rotations is ≤ 1.

Technical parameter:

No	Item	Unit	Parameter	Note
1	Rated load clamping force	kN	100
2	Rated load clamping torque	kN.m	300
3	Specification for clamping round bar forgings	mm	Φ200～φ800
4	Clamping range of crab pliers	mm	Φ50～φ1500
5	Protrusion of clamp rod (from the front end of the car body)	mm	3000	Matching with 2000 tons, meeting the requirement that the front end of the jaw reaches the center line of the forging hydraulic press.
6	Rail surface elevation	mm	±0
7	The horizontal lower limit position of the clamp rod is away from the zero plane of the foundation.	mm	eight hundred
8	The horizontal limit position of the clamp rod is away from the zero plane of the foundation.	mm	3000
9	Lifting stroke of clamp rod	mm	2200
10	Up-and-down tilt and left-and-right swing speed of the clamp rod	°s	0~3
11	Clamp rod rotation speed	r/min	0～20	Stepless speed regulation
12	Accuracy of rotary positioning of clamp rod	degree	≤±1
13	Traveling speed of cart (with 10 tons forgings)	mm/s	0～500	Stepless speed regulation
14	Clamp rod parallel vertical speed	mm/s	0-150
15	Left-right movement speed of pliers body	mm/s	0-100
16	Clamping speed of jaws	mm/s	100
17	Lateral displacement distance of clamp rod	mm	>+200
18	Horizontal swing angle of clamp lever up, down, left and right	degree	Shi 7	Crab pliers touch the ground
19	Walking accuracy of cart	mm	Shi 5
20	Overall stroke	mm	15000
21	Maximum acceleration of cart walking	m/s2	2	With 10 tons forgings
22	Gauge of cart	mm	3000	arrange for the time being
23	Gross power	kw	About 110
24	Pressure	Mp	16/25

Advantages:

1.Use ANSYS software to analyze the mechanics of the whole car body (static analysis, dynamic analysis, natural frequency analysis of the whole equipment, etc.).

2.The structure of the clamp part is reasonable, durable, adjustable in clamping force and high in clamping torque.

3.The rotating parts of the pliers rotary drive system have stable support, high positioning accuracy and great driving power driven by hydraulic motor.Under the eccentric forging load, the forging can also be clamped well, and the rotary drive does not deviate. At the same time, the drive can ensure high rotation speed and acceleration, and high forging efficiency can be obtained.

4.German Rexroth high-frequency response proportional directional valve is used for control. Compared with the conventional proportional valve, the response time is increased from 240ms to 60ms, which improves the sensitivity of adjusting the rotating speed of the tong head. It has the performance of conventional proportional amplification, so that the car body can run smoothly when starting and stopping, and the speed is infinitely adjustable.