Manual: Aluminium Bar Bending Machine

1. Foreword

2. Scope of Application

3. Equipment Overview

3.1 Basic Structure

1. Frame System: It is the main bearing structure of the equipment, made of high-strength steel plate welding or profile assembly, with high rigidity and stability, to ensure that the equipment does not deform during the bending process.
2. Bending Execution System: The core working part of the equipment, including bending die, bending shaft, driving motor (servo motor or hydraulic motor), transmission mechanism, etc., which completes the bending action of aluminium bars through the rotation of the die and the driving of the power system.
3. Clamping and Positioning System: Composed of pneumatic clamping cylinder, positioning baffle, pressure plate, etc., it is used to fix the aluminium bar firmly during bending, prevent displacement and deflection, and ensure the bending accuracy.
4. Control System: Including touch screen, operation button panel, PLC controller, servo driver, etc., which realizes the setting of bending parameters (angle, length, speed), automatic operation control and fault alarm display.
5. Feeding and Discharging System: Consisting of feeding roller table, discharging bracket, conveying roller, etc., it facilitates the loading of raw aluminium bars and the unloading of formed aluminium frames, improving operation efficiency.
6. Safety Protection System: Including emergency stop button, safety grating, protective cover, overload protection device, etc., to prevent personal injury and equipment damage caused by misoperation.

3.2 Working Principle

3.3 Technical Parameters

1. Applicable aluminium bar width: 6mm-20mm
2. Applicable aluminium bar height: 5mm-30mm
3. Bending angle range: 0°-180° (stepless adjustment)
4. Bending accuracy: ±0.5°
5. Maximum bending length: 6000mm
6. Driving mode: Servo motor drive / hydraulic drive
7. Working air pressure: 0.4-0.6MPa
8. Power supply: 380V 50Hz three-phase four-wire
9. Overall dimension: (length×width×height) 2500mm×800mm×1500mm (conventional model)
10. Weight: About 800kg-1200kg

4. Pre-operation Preparation

4.1 Personnel Preparation

1. Operators must be over 18 years old, in good health, and have received special equipment operation training, familiar with the structure, performance, operating procedures and safety precautions of the Aluminium Bar Bending Machine, and hold a post certificate before taking up their posts.
2. Operators must wear standard labor protection equipment, including anti-pinch gloves, anti-static work clothes, safety shoes, and protective goggles (when cutting or processing special aluminium bars). It is forbidden to wear loose clothes, scarves, jewelry, or have long hair unbound, so as to avoid being involved in the rotating parts of the equipment.
3. Non-operators are strictly prohibited from entering the equipment working area, and obvious warning signs such as "No Unauthorized Operation" and "Danger, Keep Away" shall be set up at the operation site.

4.2 Equipment Inspection

1. Appearance and Structure Inspection: Check the appearance of the equipment for deformation, damage or loose parts, check the welding part of the frame for cracks, and check the fastening bolts of each component (such as die, clamping cylinder, motor base) for looseness, and tighten them in time if any.
2. Power and Air Supply Inspection: Check whether the power cord, plug and socket of the equipment are intact, whether the wiring is firm, and whether the leakage protector is normal. For pneumatic clamping models, check the air compressor, air pipeline and air filter for air leakage, blockage or water accumulation, and adjust the air pressure to 0.4-0.6MPa. Drain the water in the air storage tank and filter regularly to prevent moisture from entering the pneumatic components.
3. Mechanical Transmission Inspection: Check the bending die, transmission gear, chain, belt and other transmission parts for wear, deformation or damage, check whether the lubrication is sufficient, and add lubricating oil or grease according to the regulations if necessary. Manually rotate the bending shaft to check whether it rotates smoothly without jamming or abnormal noise.
4. Control System Inspection: Turn on the power supply of the equipment, check whether the touch screen and operation panel are lighted normally, whether the display data is accurate, and test the functions of start, stop, emergency stop, parameter adjustment and other buttons to ensure that all control functions are sensitive and effective. Check the PLC controller and servo driver for fault alarms, and eliminate the alarms in time if any.
5. Die and Accessory Inspection: Select the bending die matching the specification of the aluminium bar, check the die for wear, cracks or burrs, and replace it in time if it is damaged. Check the positioning baffle, pressure plate and clamping block for wear or deformation, and adjust or replace them to ensure the positioning accuracy.

4.3 Material and Tool Preparation

1. Select qualified aluminium spacer bars that meet the production requirements, check the appearance of aluminium bars for scratches, deformation, oxidation or impurities, check the dimensional accuracy (width, height, thickness), and prohibit the use of unqualified aluminium bars that do not meet the bending requirements.
2. Prepare auxiliary tools, such as hexagon wrench, screwdriver, torque wrench, cleaning cloth, lubricating oil, measuring tools (angle ruler, tape measure, vernier caliper), etc., to ensure that the tools are complete and intact.
3. Prepare the product drawings or process documents, confirm the bending parameters of aluminium bars (bending angle, side length, quantity, etc.), and input the parameters into the control system in advance for trial bending verification.

5. Standard Operation Procedures

5.1 Equipment Startup

1. Turn on the main power switch of the equipment, and then turn on the power supply of the control system, PLC and touch screen in sequence. Wait for the system to start and self-check, and confirm that there is no fault alarm before proceeding to the next operation.
2. For hydraulic drive models, turn on the hydraulic pump motor, run it idly for 3-5 minutes, check the hydraulic system for oil leakage, abnormal noise or overheating, and confirm that the hydraulic pressure is within the normal range.
3. For pneumatic models, open the air supply valve, check the air pressure gauge to ensure that the air pressure is stable at 0.4-0.6MPa, and test the action of the clamping cylinder to ensure that the clamping and loosening actions are flexible and in place.

5.2 Parameter Setting

1. Enter the parameter setting interface of the touch screen, input the bending parameters according to the product process requirements, including aluminium bar specification, bending angle, left and right side lengths, bending speed, clamping pressure, etc.
2. Set the springback compensation value according to the material characteristics of the aluminium bar (the springback of aluminium bars is generally 1°-3°, which can be adjusted according to the actual trial bending results).
3. For batch production, store the set parameters in the system program, name the program according to the product model, and call it directly during subsequent production to improve efficiency.
4. After setting the parameters, double-check to confirm that the input data is correct, and then save the parameters and exit the setting interface.

5.3 Aluminium Bar Loading and Positioning

1. Place the qualified aluminium bar flat on the feeding roller table, push it to the positioning baffle of the equipment, and adjust the position of the positioning baffle to ensure that the bending point of the aluminium bar is aligned with the center of the bending die.
2. Start the clamping mechanism (manual or automatic), and the clamping cylinder drives the pressure plate to press the aluminium bar firmly to prevent the aluminium bar from moving or rotating during the bending process. The clamping pressure should be appropriate, not too large to deform the aluminium bar, nor too small to cause insufficient clamping.
3. Use a measuring tool to recheck the positioning size of the aluminium bar, confirm that the bending position and length meet the process requirements, and then proceed to the bending operation.

5.4 Bending Operation

5.4.1 Manual Bending Mode

1. Select the manual operation mode on the control panel, and operate the manual button or joystick to control the bending die to rotate slowly, and observe the bending state of the aluminium bar in real time.
2. When the bending angle reaches the set value, the equipment will automatically stop or stop manually, and keep the pressure for 1-2 seconds to eliminate the springback of the aluminium bar.
3. Operate the loosening button to release the clamping mechanism, take out the bent aluminium bar, and use an angle ruler and tape measure to check the bending angle and size accuracy. If the accuracy is unqualified, readjust the springback compensation value and parameters for trial bending again.

5.4.2 Automatic Bending Mode

1. Select the automatic operation mode on the touch screen, call the pre-stored product program, and confirm that the parameters are correct.
2. Press the automatic start button, the equipment will automatically complete the actions of clamping, bending, pressure maintaining, loosening and resetting in sequence according to the set program.
3. During the automatic operation, the operator shall stand in the safe area outside the safety grating, observe the operation state of the equipment in real time, and pay attention to whether there is abnormal noise, aluminium bar deformation or equipment failure.
4. After the bending of a single aluminium bar is completed, the equipment will automatically reset and wait for the next feeding. For batch production, repeat the loading and start operation until the production task is completed.

5.5 Trial Bending and Batch Production

1. Before formal batch production, conduct trial bending on 2-3 aluminium bars, check the bending angle, side length, flatness and appearance quality of the formed aluminium frame, and confirm that all indicators meet the process standards.
2. If the trial bending product is unqualified, analyze the causes (such as parameter setting error, die mismatch, positioning deviation, aluminium bar quality problem), adjust the parameters or replace the accessories in time, and conduct trial bending again until the product is qualified.
3. After the trial bending is qualified, carry out formal batch production, and conduct random inspection on the formed products at regular intervals (every 50-100 pieces) to ensure the stability of product quality.

5.6 Equipment Shutdown

1. After completing the production task, press the stop button to stop the operation of the equipment, and reset the bending die and clamping mechanism to the initial position.
2. For hydraulic drive models, turn off the hydraulic pump motor first, and then turn off the main power supply; for pneumatic models, close the air supply valve first, and then turn off the power supply.
3. Clean the residual aluminium chips, dust and impurities on the equipment surface, roller table and die, wipe the equipment with a clean cloth, and apply anti-rust oil on the die and metal parts if necessary.
4. Hang the "Shutdown for Maintenance" or "No Operation" warning sign on the operation panel, and record the production data, operation time and equipment status in the equipment operation log.

6. Safety Precautions

6.1 Basic Safety Rules

1. It is strictly forbidden to operate the equipment with diseases, fatigue, drunk or distracted mental state, so as to avoid misoperation.
2. During the operation of the equipment, it is forbidden to extend hands, arms or any parts of the body into the bending working area, and it is forbidden to touch the rotating die, transmission parts and high-temperature components (hydraulic motor, servo motor) with bare hands.
3. Do not place tools, aluminium bars or other sundries on the equipment frame, control panel and safety protection device to avoid affecting the equipment operation or causing safety accidents.
4. The equipment must be reliably grounded to prevent electric shock accidents. Do not disassemble or modify the electrical components, control circuit and mechanical structure of the equipment without authorization.
5. In case of power failure or air failure during operation, immediately press the emergency stop button, cut off the power supply and air supply, and wait for the power supply and air supply to return to normal before restarting the operation after inspection.

6.2 Special Operation Safety

1. When replacing the bending die, the equipment must be completely shut down, the power supply and air supply/hydraulic supply must be cut off, and the operation can be carried out only after the die is completely stopped. Use special tools to disassemble and assemble the die to avoid injury caused by die falling.
2. When bending special-shaped or ultra-long aluminium bars, add auxiliary support brackets to prevent the aluminium bars from deforming or swinging during the bending process, and arrange special personnel to assist in feeding and discharging.
3. When the equipment is running with overload or abnormal noise, immediately press the emergency stop button, cut off the power supply, check the cause of the fault, and it is forbidden to continue operation with fault.
4. The safety grating, protective cover and emergency stop button of the equipment shall not be dismantled or shielded at will, and regular inspection shall be carried out to ensure their effectiveness.

6.3 Emergency Handling

1. In case of personal injury (such as pinch, scald, electric shock), immediately cut off the power supply and air supply, carry out first aid measures, and send to the hospital for treatment in time.
2. In case of equipment failure (such as die jamming, hydraulic oil leakage, motor overheating), press the emergency stop button immediately, stop the operation, record the fault phenomenon, and notify the professional maintenance personnel for repair.
3. In case of fire caused by electrical short circuit or hydraulic oil combustion, immediately cut off the power supply, use dry powder fire extinguisher to put out the fire, and it is forbidden to use water to put out the electrical fire.

7. Equipment Maintenance and Upkeep

7.1 Daily Maintenance (Once per Shift)

1. Clean the equipment surface, die, roller table and working area, remove aluminium chips, dust and impurities, and keep the equipment clean.
2. Check the fastening of bolts, nuts and connectors of each component, and tighten them in time if loose.
3. Check the air pressure, hydraulic pressure and lubrication state of the equipment, add lubricating oil or grease to the transmission parts (bearing, gear, chain) according to the regulations, and check the hydraulic oil level and oil quality.
4. Test the functions of emergency stop button, safety grating and control buttons to ensure they are normal.
5. Record the daily maintenance situation in the equipment maintenance log.

7.2 Weekly Maintenance (Once a Week)

1. Thoroughly clean the inside of the equipment, including the hydraulic oil tank, air filter, control cabinet, remove dust and impurities, and check the wiring in the control cabinet for looseness.
2. Check the wear of bending die, clamping block, positioning baffle and transmission parts, and replace the seriously worn parts in time.
3. Drain the water and impurities in the air storage tank, air filter and hydraulic oil tank, and check the hydraulic oil for deterioration or pollution. If necessary, replace the hydraulic oil and filter element.
4. Calibrate the bending angle and positioning size of the equipment, and adjust the deviation to ensure the processing accuracy.
5. Check the operation of the servo motor, hydraulic pump and clamping cylinder, and eliminate abnormal noise and oil leakage.

7.3 Monthly Maintenance (Once a Month)

1. Conduct a comprehensive inspection of the electrical system, including the PLC controller, servo driver, touch screen, sensor, etc., check the wiring for aging or damage, and replace the damaged wires in time.
2. Perform lubrication maintenance on all transmission mechanisms, replace the lubricating oil or grease that has deteriorated or exceeded the service life, and adjust the tightness of the chain and belt.
3. Check the sealing performance of the hydraulic system and pneumatic system, replace the aging sealing ring and oil seal, and eliminate oil leakage and air leakage faults.
4. Calibrate the pressure gauge, temperature sensor and other measuring instruments of the equipment to ensure the accuracy of measurement data.
5. Conduct a comprehensive test run of the equipment, check the operation status of each system, and deal with potential faults in advance.

7.4 Annual Maintenance (Once a Year)

1. Conduct a comprehensive disassembly and inspection of the equipment, check the wear of key components such as frame, bending shaft, bearing, and carry out repair or replacement according to the wear degree.
2. Replace all hydraulic oil, lubricating oil, filter element and sealing parts of the equipment, and clean the hydraulic oil tank and lubrication system.
3. Conduct a comprehensive calibration of the control system, update the system program if necessary, and optimize the bending parameters.
4. Conduct a safety performance evaluation of the equipment, including safety protection device, grounding system, overload protection, etc., to ensure that the equipment meets the safety standards.
5. After the annual maintenance is completed, conduct a comprehensive test run and acceptance, and record the maintenance content and acceptance results in the equipment file.

8. Troubleshooting of Common Faults

8.1 Inaccurate Bending Angle

1. Fault Causes: Incorrect springback compensation parameter setting, wear or deformation of bending die, loose positioning baffle, unstable air pressure/hydraulic pressure, damage of angle sensor.
2. Solutions: Readjust the springback compensation value according to the trial bending results; replace the worn or deformed bending die; tighten the positioning baffle and recalibrate the positioning size; check the air compressor/hydraulic pump to stabilize the pressure; replace the damaged angle sensor and recalibrate.

8.2 Aluminium Bar Deformation or Scratches During Bending

1. Fault Causes: Improper clamping pressure, burrs or wear on the die and clamping block, unqualified aluminium bar material, misalignment of bending point.
2. Solutions: Adjust the clamping pressure to an appropriate value; polish or replace the die and clamping block with burrs or wear; replace qualified aluminium bars; recalibrate the bending point position to ensure alignment with the die center.

8.3 Clamping Mechanism Fails to Clamp or Loosen

1. Fault Causes: Insufficient air pressure/hydraulic pressure, blockage of air pipe/hydraulic pipe, damage of clamping cylinder, failure of solenoid valve, loose circuit connection.
2. Solutions: Adjust the air pressure/hydraulic pressure to the normal range; clean the blocked pipeline; replace the damaged clamping cylinder; check and replace the faulty solenoid valve; tighten the loose circuit connector.

8.4 Equipment Abnormal Noise or Vibration

1. Fault Causes: Insufficient lubrication of transmission parts, loose fastening bolts, wear or damage of bearing and gear, unbalanced bending die, overload operation.
2. Solutions: Add lubricating oil or grease to the transmission parts; tighten all loose fastening bolts; replace the worn bearing and gear; recalibrate the balance of the bending die; reduce the processing load to avoid overload operation.

8.5 Hydraulic System Oil Leakage

1. Fault Causes: Aging or damage of sealing ring, loose joint of hydraulic pipe, crack of hydraulic oil tank, damage of hydraulic pump shaft seal.
2. Solutions: Replace the aging sealing ring; tighten the loose hydraulic pipe joint; weld or replace the cracked hydraulic oil tank; replace the damaged hydraulic pump shaft seal.

8.6 Control System Failure (Touch Screen No Display, Parameter Cannot Be Set)

1. Fault Causes: Power supply abnormality, loose connection of control line, damage of touch screen or PLC controller, system program error.
2. Solutions: Check the power supply and restore normal power supply; tighten the loose control line connector; replace the damaged touch screen or PLC controller; restart the system or reload the program to restore the normal operation of the control system.

9. Storage and Transportation of Equipment

9.1 Equipment Storage

1. The equipment should be stored in a dry, ventilated, dust-free and non-corrosive gas environment, away from heat sources, direct sunlight and rain.
2. Before storage, clean the equipment thoroughly, apply anti-rust oil on all metal parts and die, cover the equipment with a dust cover, and block the hydraulic pipe and air pipe interface to prevent dust and impurities from entering.
3. The equipment should be placed flat on a solid ground, and the support points should be set according to the requirements to avoid deformation of the frame. Regular inspection should be carried out during storage, and anti-rust and moisture-proof treatment should be done well.

9.2 Equipment Transportation

1. The equipment transportation should be carried out by a professional logistics company, and the transportation vehicle should have a fixed device to prevent the equipment from shaking or colliding during transportation.
2. Before transportation, fix all movable parts of the equipment (such as bending die, clamping cylinder, roller table) with fixtures, remove the easily damaged parts (such as touch screen, sensor) and pack them separately for transportation.
3. During loading and unloading, use a forklift or crane that meets the lifting requirements, and operate in accordance with the hoisting specifications to avoid impact or tilting of the equipment. The lifting point should be selected at the designated position of the equipment frame.
4. During transportation, cover the equipment with a rainproof and dustproof cloth to prevent rain, snow and dust from eroding the equipment.

10. Supplementary Provisions

1. This manual is the basic operation standard of the Aluminium Bar Bending Machine, and the operator shall strictly abide by it. If there is any conflict with the special instructions of the equipment manufacturer, the manufacturer's instructions shall prevail.
2. The enterprise shall formulate corresponding operation management system and maintenance system according to this manual, and assign special personnel to be responsible for the management and maintenance of the equipment.
3. Any modification, transformation or upgrade of the equipment must be approved by the equipment manufacturer or professional technical personnel, and shall not be carried out without authorization.
4. The operator shall be responsible for the equipment damage and personal safety accidents caused by violation of this manual.
5. This manual shall be kept properly, and the lost or damaged manual shall be reported to the equipment management department in time for replacement. The technical department of the enterprise is responsible for the interpretation and revision of this manual.