Jinan Weili Machine Co., Ltd.

LWJ01 Automatic Bar

Bending Machine

Instruction Manual

Jinan Weili Machine CO.,LTD

ADD:1-1407 Meilin Mansion Wuyingshan Middle Road Tianqiao

district Jinan city
Shandong province China
Tel: +86 0531 6880 1308

Fax： +86 0531 6880 1308

Website:www.weiliglass.com

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Introduction

Thank you for choosing our equipment for insulating glass

production!

Please read the OPERATING INTRUDUCTION carefully

before operating the equipment. The operator must operate the
equipment strictly according to the INTRUDUCTION, so that
the equipment can work in best conditions. (We won't be
responsible for the problems caused by wrong operation.)
Honestly welcome the feedback and advice to us in the course
of using the machine, so that we can offer a better service to
you.

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Catalog

Chapter One. Usage and Main Parameters

Chapter Two. Structural Characteristics and
Functions

Chapter Three. Installation and commissioning

Chapter Four. Maintenance

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Chapter One. Usage and Main Parameters

Full Automatic Spacer Bending Machine is auxiliary equipment for fabrication of
insulating glass. In China, U-type aluminum insulating glass dominates the majority of the
market, but at present, most of the supporting frames for the U-type aluminum insulating
glass were fabricated by assembling of 4 different sections of aluminum bars. With the
Full Automatic Spacer Bending Machine may form aluminum convex polygon frame of any
desired shape by use of one single aluminum bar. With so many unique characteristics,
the equipment is indispensable for fabrication process of insulating glass.
Power supply 3p;380V 50Hz
Total power 2.5KW
Air pressure ≥0.8Mpa
Min spacer frame size 250*380mm
Max spacer frame size 2500*3000mm
Spacer width range 5.5mm~24mm
Overall dimension 105000mm*2100mm*2200mm
Size tolerances ≤±0.2mm
Angle tolerances ≤±1
Spacer storage area 4
No. of shapes 32

Control system: with adoption of PLC programmable controlling element of SIEMENS

from Germany and with program capacity of 8000 bits, the system has 14 input controlling
signals and 34 output controlling signals, including 2 channels for step-by-step impulse
controlling signals. These signals can be utilized for digital accurate control of various
parameters for products. With strong calculation and tolerance capacity, the control
system makes programmable control of the equipment very easy.
Operational interface: Touch screen under brand name of WEINVIEW
produced in Taiwan was used. With up to 120 interaction windows, the
screen has powerful human-machine interaction capacity. Almost all
parameters can be controlled and adjusted simultaneously. Even
freshman can learn and master basic utilization techniques within a short
time.
Electric elements: only imported or top-grade domestic electric elements
should be used on the equipment. Major elements adopted include
products of SIEMENS from Germany, AUTONICS from South Korea, and
AIRTAC from TAIWAN,CHINA. All these elements were carefully selected
and inspected, and only those passed aging tests can be used for
equipment fabrication.
Processing of equipment body: All key spare parts were hardened by adoption
of top-grade materials. To ensure reliability and durability of key parts, all
external surfaces were galvanized or treated. The equipment body was

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treated by using plastic-forming technologies. All panels were fabricated
by use of custom made industrial multi-layer board to ensure flatness and
resistance to wear.

Note: The aluminum spacer must be bent.

Chapter Two. Structural Characteristics and Functions

1.1 Mechanical section

1.1.1 Bending Machine

Bending Machine is composed by equipment body rack, aluminum frame
back panel, automatic adapter system , material length metering system ,
digital control step by step feeding system, digital control bending system,
automatic cutting mechanism, electric control system, power control system,
control box and touch screen man-machine interface.

7.1.1.1Touch screen, 7.1.1.4 Bar transferring system, 7.1.4.5

Step-by-step system, 7.1.1.7 Automatic cutoff, 7.1.1.6 Digital controlled
bending, 7.1.1.2 Equipment and supporting rack, 7.1.1.3 Aluminum
frame back panel

1.1.1.1 Aluminum frame back panel: Made of industrial grade multi-layer

wood board, it can be used as platform for aluminum bar during
formation of aluminum frame. The touch screen man-machine
interface was installed on the rack. Entire structure can be lowered
down through screw motion to facilitate transportation of the
equipment over a long distance.

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1.1.1.2 Automatic adapter system: the system is composed by connector

positioning elements and aluminum bar positioning elements. As
soon as the tail section of aluminum bar reached alarming point,
adapter system may automatically locate the tail section of aluminum
bar and wait for automatic connection of next aluminum bar.

1.1.1.3 Digital control step-by-step feeding system: The system can perform
operations required by step-by-step length signal of the control
system. With auxiliary arc equipment, equipment may be use to form
arc frame.

1.1.1.4 Digital control bending system: Bending angles of the digital control
bending system can be adjusted and controlled accurately. The
bending angle can be anything between 30°and180°. Cooperate with
software, equipment can form arc with Minimum radius of 80mm.

1.1.1.5 Automatic cutting mechanism: during initial feeding operation or

when the first frame-bending operation was finished, cutting
mechanism may cut aluminum bar automatically. During connector
yielding calculation, the system may also cut surplus materials.

1.1.1.6 Electrical control system: Electrical control system is the core section
of entire system. The controlling software of the equipment was
installed in SIEMENS PLC. All of the controlling instructions,
calculation works, input and output signals, system status monitoring
and communication with operators would be accomplished by this
part.

1.1.1.7 Pneumatic power control system: the pneumatic power system is

composed by several solenoid valves, corresponding gas supply
channels, many pneumatic elements and controlling circuit. The

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system is responsible for programmable control of complex activities
of the equipment.

Notice: Quality of adjustment in pneumatic circuit and pneumatic elements is

critical to overall performance of the equipment. No adjustment
activities should be conducted on pneumatic elements until
percentage of success is high enough. In addition, all parameters
before adjustment should be recorded duly, and in case of
adjustment failure, the system can be restored back to original status.

1.1.1.8 control box: major parts of electrical control system were installed
within the control box. Notice: Cares should be taken to avoid any
damaging factors around the control box. Control box doors should
be closed during periods other than for equipment maintenance.

1.1.1.9 Touch screen software interface: touch screen is installed on the front
left side of Bending Machine back panel. Large quantity of data input
required by operators to operate the equipment and other information
required by operators to understand operating conditions of the
equipment were communicated through the touch screen. In a sense,
visualize operational interface is very helpful for operators, with
textual descriptions, it is very easy for operators to accomplish data
input, retrieval and parameter modification operations.

Notice: Though the surface of touch screen has been treated by specialized
process, improper utilization still has negative impacts on service life
of the screen, and in extreme cases, improper use may damage the
machine. Improper utilization includes knocking, scratching, pointing
with sharp articles, clapping, cleaning with organic solvent and
operated with oil-stained hands. In short, touch screen should be
operated by slightly press corresponding push buttons.

1.1.1.10 Foot Switch, ON/OFF and STOP Push button: these buttons are
responsible for starting bending instructions, switch on and/off
equipment and crash stop of the equipment respectively.

1.2 Stock stack

1.1.2.1 Stock stack includes four movable feed trenches, feeding platform,
automatic feeding system, feed trench exchange mechanism, feed
trench detection systems and elements.

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1.1.2.2 Feed trench, 1.1.2.3 Feeding platform, 1.1.2.5 Feed trench

exchange mechanism 1.1.2.6 Trench detection, 1.1.2.7Feed trench
foot switch, 1.1.2.4 Automatic feeding system

1.1.2.2 Feed trench: the four feed trenches can store one to four kind(s) of
aluminum bars with same width or different width. The equipment can
utilize these raw materials automatically during normal operation.
Positions of four feed trenches can be changed easily.

1.1.2.3 Feeding platform: Feeding platform may provide operation platform

for operators to add more bars into the feed trench.

1.1.2.4 Automatic feeding system: As soon as the equipment was mobilized,

automatic feeding system may transfer aluminum bar to
pre-determined locations. During bending operations, as soon as the
bending aluminum bar reached its tail section, the automatic feeding
system may complete the continuous action of the aluminum bar to
ensure continuity of the bending operation and actualize operations
without residues.
1.1.2.5 Feed trench exchange mechanism: As soon as aluminum bars
contained in feed trench were used up, the feeding system can be
exchanged to use feed trench with aluminum bars contained. It is
also impossible to install automatic feeding exchange system to
conduct exchange of feed trenches automatically.

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1.1.2.6 Feed trench foot switch: The switch can be used to unlock the locking
system, operate feed trench exchange mechanism.
1.3 Programmable control system for touch screen

1.3.1 Programmable control system includes cover, master display,

rectangular frame section, irregular arc-shaped frame section,
Manual Adjustment Interface, Function Setup interface, Internal
parameter setup interface, “Clock settings” interface, HELP interface
and others;

1.3.1.1 Cover: pop-up display during equipment starting, the display contains
information of equipment manufacturer, version of current software,
name of the company with equipment available and other relevant
information;

1.3.1.2 Main display: Provide display for selection of bending operation,

display for counting of product, alarming information and bending
parameters for the current rectangular frame.

1.3.1.3 Rectangular frame Operational interface: rectangular frame operational

interfaces can be classified into 4 groups, and these 4 groups are
corresponding to parameters of aluminum frame made from
aluminum bars contained in 4 different aluminum-bar feeding
trenches. It is also possible set parameters for 4 different batches of
fabrication tasks. Parameters for rectangular frame can be inputted
and modified in the display as required by figures and textual
contents.

1.3.1.4 Irregular arc frame Operational interface: irregular arc frame

operational interface include 9 groups of displays, it can be utilized to
input bending parameters for aluminum frames of one aluminum bar
to convex polygon frames composed by 8 straight edges and arcs.

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Parameters for rectangular frame can be inputted and modified in the
display as required by figures and textual contents.

1.3.1.5 Manual Adjustment Interface: Manual Adjustment Interface can provide

operation for specific operational element during equipment
commissioning or during specific operations. It may also be used to
adjust specific element or function individually. Manual operation
may also be used during formation of some aluminum frame with
special configurations.

1.3.1.6 Function setup interface: Function setup

interface can be sued to detect corresponding
code inside of the equipment. Upon obtaining
authorization, use this interface may activate
internal functions of the equipment. At the same
time, users may pre-set or modify their logon
password to protect key internal parameters.

1.3.1.7 Internal parameter setting interface: The interface can be used for
setting of some inherent parameter and correction factors required for
equipment operation.

Notice: Do NOT modify various parameters without clear

understanding of these exact meanings, otherwise the equipment may
perform improperly or totally failed.

1.3.1.8 “Clock settings” interface: The interface can be used for setting of
system time. Accordingly, the equipment may have colander and
clock functions.

1.3.1.9 Info window: popup info window may inform operators about current

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status of the equipment and possible problems.

1.3.1.10 Status bar, Shortcut Menu: status bar indicates the operating status of
the touch screen. Shortcut Menu may be used to enter desired
interface directly.

1.4 Loading of feed trench (before equipment starting up)

1.4.1 Depth of each feed trench is about 230mm. The trench is capable of
store about 32 aluminum bars .Accordingly, it is quite easy to calculate
required quantity of aluminum bars required in feed trench for each batch of
aluminum frames with their dimensions and quantities known.

Notice: Before load aluminum bar into trenches, it is necessary to

check flatness of each end of aluminum bar since it may affect
connection quality of aluminum bar. Generally speaking, newly
unpacked aluminum bar can be loaded into the feed trench directly.
Slightly deformed aluminum bar can also be placed into feed trench if
necessary remedial measures were taken. All flattened or crashed
aluminum bar should be cut to remove damaged sections before they
can be placed in the feed trench.
1.4.2 Independent single input system.

1.4.3 After all Material are put in the feed trench, make sure the right
degrees of the Aluminum should be aligned with the baffle.

1.4.4 Step on “Foot Switch” if necessary. As soon as the locking mechanism

was released, pull feed trench and change feed trench and repeat material
loading procedures.

Notice: during transferring of aluminum bar in feed trench into Bending

Machine, the equipment may lock off the operation function of the
feed trench. This locking mechanism may eliminate possibility of
damages to bending aluminum bar inside the equipment.

Chapter Three. Installation and commissioning

Please arrange equipment installation space with consideration to
equipment dimensions specified in Machine Parameter. Left end of the
equipment is the section for material feeding. It is necessary to adopt spaces
raw aluminum bar (max. 6000mm) and manual adapter operating space even
for equipment. Preserved space should be 8000mm or greater. Though
equipment equipped with feed trench system, it is recommended to preserve

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operating space of greater than 1000mm on the left end of feed trench. The
space should be no less than 500mm. Otherwise; it would be difficult for
feeding of 6000mm raw aluminum bars.
There are spaces for product formation on the right end of the equipment. In
principle, there is no requirement for reserved spaces. But with
consideration to accessibility of the largest possible finished frames, it
is suggested to preserve operating space with length of more than
1000mm. During emplacement of the equipment, spaces required for
connection with the next work procedure automatic loading of
molecular sieve should be considered.
Maintenance access space of more than 1000mm should be preserved in the
back of the equipment to ensure free movement of door for the
control box. In addition, the space may ensure free access of
maintenance operators for equipment maintenance operations.
The equipment should be installed on solid concrete floor or other industrial
grade floor with horizontal height difference of no more than 20mm.

3.1.1 Atten: The equipment is equipped with industrial shock-preventative

anchor bolts and the shocks produced by the equipment itself are
ignorable. Cares should be taken to keep the equipment away from
equipment with strong shocks or other shocking sources. Strong
shocks may loosen elements of the equipment and produce negative
impacts over normal operation of the equipment.

3.1.2 Care: Equipment should NOT be installed in dusty environments or

environment with high humidity. These conditions may cause
uncertain failures in electric elements.

3.1.3 Frontal side of the equipment (especially touch screen) should be

kept away from sunshine or other strong radiation sources because
strong irradiation may reduce visibility of the touch screen and
accelerate its aging. All these conditions may have negative impact
over proper functioning of the equipment.

3.2 Power supplies for equipment installation

3.2.1 Notice that power supplies for equipment include power driven
elements and pneumatic elements. Requirements for gas supply are:
dry compressed air with pressure within range of 0.6 ~0.8Mpa, gas
consumption during continuous production <10L/min, recommended
optimal operation pressure is 0.6Mpa. Equipment pressure can be
adjusted to required extent by use of the pressure-adjusting valves of
the equipment. Over pressure can be adjusted into desired range by

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use of pressure valve located on the equipment. Though oil water
separator system was installed within the equipment, it is
recommended to install water-filtering utilities in frontal gas-supplying
system. Water contents contained within the compressed air may be
corrosive to pneumatic elements and accelerate failure of these
pneumatic elements.
3.2.2 Care ！ Power supply for the equipment is single phase electric of
220V AC and the capacity of the equipment in continuous production
status is 2kW. Anti-shocking protective utilities are required on the
power supply system.
3.2.3 Warning！ Proper equipment grounding is required before connecting
the equipment with power supply. The live wire and zero wire should
be connected with the control box as required.

3.2.4 Attention: Digital power supply was adopted within the control box,
and without proper grounding, the equipment surface may
accumulate inductive potential. Operators touching this equipment
may slightly feel the electrifying sensation, and at this time, it is
necessary to inspect the grounding system of the anchoring
equipment.

3.2.5 Care ！ No installation, maintenance or repairing works can be

performed until the power supply of the equipment was cutoff.

3.2.6 Care ！ Upon replacement of spare parts or completion of

maintenance works, it is necessary to conduct motor-driven
adjustment or manual adjustment. Qualified staffs should conduct all
adjustment works. Coordinated commission conducted in front and at
back of the equipment simultaneously should be conducted with
satisfactory communication between the involved parties.

3.2.7 Warning！ Qualified staffs should conduct all maintenance works on

electric circuit.

3.3 Equipment is in place

3.3.1 The equipment in place can be determined in accordance with

specific conditions on site;
3.3.2 Shocking-proof anchor bolts should be assembled properly underneath
the equipment rack before emplacement of the Bending Machine (to ensure
transportation safety, Shocking-proof anchor bolts were delivered as
attachment). Upon completion of anchor bolt installation, other tools may be
mobilized to relocate the equipment to desired installation location.

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As soon as the bending machine was positioned properly. Pop up the back
panel by use of the back panel supports (if the back panel is in its lowering
down position). Supports for back panel were delivered as accessories of the
equipment. To facilitate transportation, the positioning U-steel for the back
panel was reversibly installed on the rack of back panel. It is necessary to
dismantle the positioning steel and restore it to proper position by lifting up the
back panel. Install the anchor pin as soon as the installation holes for the back
panel, supporting pillar and the equipment rack overlapping with each other. In
this way, the back panel can be restored to the normal position.
3.3.3 Install frontal sideboard, frontal cover, frontal table, and frontal cover
board and remove all discarded packages and other materials;
3.3.4 Make sure jointing of back panels conforms to “sequential
displacement” requirements for fabrication of aluminum frame
(During fabrication of aluminum frame, to prevent the end of
aluminum frame from collision with the joints of the back panel, the
back panel should be 0.1~0.5mm higher than the next back panel on
the way of aluminum frame movement).
3.3.5 Use guiding rule to confirm levelness of the equipment. Adjust
corresponding supporting bolts until the equipment conform to specified
requirements for levelness.
3.3.6 Connect the power supply and communication line for the touch screen
to corresponding terminals on the touch screen and securing the anchor
screws

Notice: It is necessary to check and secure all fixing screws. All dislocated
adjustable elements or mechanism can be secured after equipment
commissioning.

Notice: It is necessary to check looseness and dislocation of gas circuits to

ensure reliable connections.
3.3.7 Upon completion of equipment commissioning, it is necessary to
install and secure backside cover and back cover of the Bending
Machine.

3.3.8 The stock stack is located on the left of Bending Machine, while the
distance between right end of stock stack and the left end of the
Bending Machine is 20~40mm with no mechanical joints between.

3.3.9 Use guiding rule to confirm levelness of the equipment. Adjust

corresponding supporting bolts until the equipment conform to specified
requirements for levelness.

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3.3.10 Install stock platform and adjust it to desired levelness.

3.3.11 Connect pneumatic and electric elements. Connect the

gas supply and position the feed trench rack to the
ultimate position. Install one straight raw aluminum bar
into the first raw material feed trench.

3.3.12 Transfer aluminum bar to the right and slightly relocate

the stock stack till aluminum bar can easily enter the
feeding port on adapter of the Bending Machine easily.

3.3.13 Use anchor line or other acceptable method align the

feed trench on the left with the Bending Machine, and repeat
procedure 4.3.11.

3.3.14 Step on “feed trench exchange Foot switch “to exchange feed trench,
and check working status of other feed trenches.

3.3.15 If required, clearance for aluminum bars should be adjusted to cope

with specific requirements presented by aluminum bars used by
clients.

3.3.16 It is necessary to check and secure all fixing screws. All dislocated
adjustable elements or mechanism can be secured after equipment
commissioning.

4 Concepts and requirements for Automatic Spacer Bending

Machine
4.1 Understand working principles of full automatic Spacer Bending Machine.

4.1.1 Full Automatic Spacer Bending Machine is automatic auxiliary production

equipment specialized for production of high quality aluminum frames
for U-type laminated glass;

4.1.2 Through the touch screen, an man-machine interactive communication

model can be achieved, and accordingly, the equipment may obtain
parameters for 32 different sizes of aluminum frames desired by operator; or,
the operator may input parameters of convex polygons composed by up to 8
sides in arc or direct line. At the same time, the equipment may obtain
parameters for the quantity of aluminum frame to be fabricated, or other
parameters required for accurate operation of the equipment.

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Touch screen utilizes combination of figures and textual contents on its display
to facilitate quick and rational bending operations by operators. At the same
time, the touch screen can provide operating status parameters and popup
information of the equipment to operators. The internal on-line help function
can provide operators with operational helps whenever required.

4.1.3 Upon obtainment of parameters for aluminum frames, the equipment

may select automatic feeding (or manual feeding) in according with
positioning of raw materials, or the equipment may enter
automatic-bending procedures directly.

4.1.4 As soon as bending instructions were obtained from operators,

equipment may determine if the connector section of present raw material falls
in bending-forbidden zone. The so called bending-forbidden zone refers to the
extent of 50mm in front and behind the bending section of the aluminum bar,
and the 50mm in front of the finished aluminum frame. Bending operations
within this zone may lead to bending of metallic corner of the aluminum bar
and ultimately lead to fracture or deformation of aluminum frame.

As soon as the data were confirmed, equipment may automatically

determine rational bending times. Short butt ends made by the equipment can
be ignored because these are normal operation of the equipment to avoid
connectors. This is very common when making small frames and the
proportion of bending-forbidden zone is quite high. Sometimes, it would be
impossible for the equipment to avoid bending operations by displacement,
and the equipment would have to select to give up the material. This can be
eliminated in making of larger frames or the bending-forbidden zones were
skipped successfully.

4.1.5 The digital control feeding elements, composed by digital step-by-step

units, may transmit calculated accurate size data to the bending
cutter head. Actual accuracy of these data should be within extent of
±2mm for every 1000mm.

4.1.6 Digital controlled bending system may perform desired bending

operations.

4.1.7 Repeat the last two steps until the entire aluminum frame formation
procedure was completed.

4.1.8 Time consumed for fabrication of 300mm×300mm frame should be

no more than 20 sec; and the time should be no more than 55 sec for
fabrication of frames with size of 2500×2500mm.

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4.1.9 Tolerance for bending angle and side width of the rectangle frame
should be no more than 0.3mm.

4.1.10 Concave pit (or overlapping sides) on corner section of the

rectangular frame should be no more than 3％.

4.1.11 It is possible to conduct continuous bending operations automatically.

5.1 Other requirements

5.1.1 To avoid existence of any obviously irrational data, the equipment

may set data input extent and filter the input data during inputting of
data for the aluminum frames? In addition, the equipment may
prompt corresponding reminder messages;

5.1.2 During bending of aluminum frame, as we may expect, current

aluminum bar might be finished at any time. Under these
circumstances, the equipment may take this situation into
consideration and utilize the material to the full. By utilization of
rational procedure, upcoming aluminum bar may automatically
connect to the end section of the aluminum bar before. The
procedure will not interrupt current bending of aluminum bar and
ultimately ensure no materials will be discarded due to technical
reasons for current aluminum frame.

5.1.3 Digital controlled bending system may adjust bending velocity in

stepless way in accordance with various sizes of aluminum frames.
This function can provide satisfactory solution to be conflict between
high efficient, high-velocity fabrication of small aluminum frame and
low-velocity deformation-free fabrication of large aluminum frame.

5.1.4 To avoid frequent exchange and adjustment of cutter head 9A-24A

required for fabrication of aluminum frame with different width and
sizes, and to ensure conformity of aluminum frame structure and the
optimal operating mode, the equipment adopted automatic cutter
system universally used for aluminum bars of size above 6A.

5.1.5 Under abnormal conditions, the “STOP” push button can be utilized
to ensure safety of operators and relevant equipment;
5.1.6 The material of aluminum is adaptable of different need of our
customers.

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5.1.7 The equipment is equipped with energy-saving dormancy functions.
If no bending operation was performed within pre-determined time
period specified by operators, the system might enter the
energy-saving dormancy status with the minimum energy
consumption. The equipment may rapidly restore its operating mode
through normal operations, and this function can also be restricted.

5.1.8 The equipment is capable of successive bending, which can be useful

for batch fabrication of aluminum frame in large quantity since it may
automatically perform fabrication procedures continuously. This
function can also be restricted.

5.1.9 Care :elements of the equipment will be available for manual

operation under Manual Adjustment status to facilitate fine toning
operations after maintenance works.

5.1.10 Relevant parameters are capable of modification and fine-tuning.

Various parameters can be finely tuned by use of this

6.1 Gas circuit connection and pressure adjustment

6.1.1 Gas supply inlet of the equipment is located on the back of the
Bending Machine and the system adopted quick socket connection.
Female contact for quick socket connection is required on the input
side of the gas supply.

6.1.2 Upon connection of contacts for gas supply, pressure of the gas
supply might be observed on pressure gauge on water and oil
separator of the equipment.

6.1.3 If the pressure was too high, it is suggested to adjust the pressure
adjusting button in the middle section of
the water and oil separator. Pull the
button cap downward and turn the cap
leftward to adjust the pressure reading
on pressure gauge to 0.6Mpa. Otherwise,
it is necessary to turn the button
rightward. If the pressure was below
0.6Mpa when the button reached its end,
it would be necessary to check the gas circuit and gas-supplying
equipment of the gas supply system. (Figure)

Notice: If the pressure is too low, the pneumatic elements may react

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slowly or abnormally, and consequently, the
equipment may perform abnormally.

7.1 Replacement of cutter head

7.1.1 If the aluminum bar to be treated is not coincide with the cutter head
installed on the equipment, it will be necessary to replace the cutter head with
appropriate ones: Press the “STOP” push button and remove the guard cover
of the cutter head:

Notice: the equipment has two kinds of cutter heads: Fixed cutter
head for aluminum bars of 6mm in width and automatic cutter head
for bending of aluminum bars in
width of 9mm ～ 20mm. These two
kinds of cutter heads are NOT
inter-changeable.

7.1.2 Loose the anchor screws of the

cutter head and remove cutter
head;

7.1.3 Place the suitable cutter head into

cutter head trench before securing anchor screws. (Figure)
7.5.4 Switch on “STOP Pushbutton” and “ON/OFF” button to initialized the
equipment before adjustment of installed cutter head

8.1 Commissioning of cutter head

8.1.1 Click on “Quick Menu” on touch screen, and select the “manual
operation” out of the “Shortcut Menu”, and click “Quick Menu” again
to close the Shortcut Menu;

8.1.2 Select “cutter head commission” out of the “manual operation”

interface, and the button may turn into orange, which indicates that
the commissioning of the cutter head can be proceeded:

8.1.3 Place a discarded straight aluminum bar between the cutter base,
(with venting hole upward) before step on”Foot Switch”, and the
bending system may accomplish a set of bending actions
automatically.

8.1.4 Take out the aluminum bar and observe configuration of the
aluminum bar and adjust the height of the cutter head accordingly.

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8.1.5 As soon as adjustment of cutter head was accomplished, push the

“cutter head adjustment” button on touch screen to return it back to its
original dark purple.

Chapter Four. Maintenance

Equipment maintenance

1.1 Feed trench section

1.1.1 Material rack: Whenever difficulties were encountered during feeding

of raw aluminum bars, it is necessary to check installation
displacement of the material rack. Loosen of anchor bolts of material
rack may cause inclination of the feed trench. All problems
discovered should be tacked properly in timely manner.

1.1.2 Fixing of feed trench: Fixing elements for feed trench can be used to
secure 4 feed trenches. Fixing status of these trenches may directly
affect smooth transferring of raw aluminum bar into Bending Machine
or if the jointing of aluminum bars is satisfactory. When the feed
trenches were locked, try to pull the rack by force and if the resulting
displacement were over 2mm it would be necessary to adjust the
fixing mechanism.

1.1.3 Feeding material holding mechanism: If the feeding material holding

mechanism was not properly installed, it would be difficult for raw
aluminum bar to reach proper location or for jointing of two
neighboring bars. In accordance with movements of holding
mechanism, opening width of the holding utilities and the height of the
holding mechanism to suitable extent.

1.1.4 Feeding elements of material rack: Overspeed of feeding elements on

material rack may lead to strong shakes of the equipment and
rending control of adapter very difficult. At the same time, if the
movement is too slow, movements might be discontinued or
unacceptable. Suitable movement velocity is very important for
achievement of suitable material feeding results.

1.1.5 The feed trench skid should be adjusted in timely manner when raw
aluminum bars from different suppliers were adopted to cope with the
changes in raw materials. Incorrect operations may cause failure of
the cutting head.

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1.2 connector component

1.2.1 The most common problem for connector component is the failure of
adapter. Several reasons may contribute to this:

1.2.2 Fixing elements of adapter were not tight enough. Loose fixing
elements for adapter may lead to misplacement of the connector on
tail section of present aluminum bar and the head section of the next
aluminum bar. To tackle the problem, it is required to secure the
loose elements.

1.2.3 Improper movement of pneumatic elements for adapter positioning.

Pressure required for movement of pneumatic element positioning
will not be very high, generally the pressure will be in extent of
0.1Mpa～0.3Mpa.

1.2.4 Unsuitable clearance in adapter holding elements or inability to hold

aluminum bar. To tackle the problem it is required to adjust holding
clearance in accordance with thickness of the aluminum bar or
replace with corresponding elements.

1.3 Digital control step-by-step element

1.3.1 Common problems concerning digital control step by step elements

are as follows:

1.3.2 Slipping of raw aluminum bar was encountered during fabrication of

rectangular frame. It is necessary to adjust material feeding
clearance, but cares should be taken that tight clearance may cause
deformation in thickness of the aluminum bar and consequently
cause deformation of the frame. Since the driven Feeding wheel (in
the upper section) was composed by gapless complex gears, cares
should be taken during adjustment of material feeding clearance to
loose fixing screws of the complex gear before adjustment. Upon
completion of adjustment operation, clearance should be reduced to
minimum before re-secure anchor screws.

1.3.3 Slipping of raw aluminum bar was encountered during fabrication of

odd shaped frames. At this time, it is necessary to adjust driving
elements. Composition of driving elements is quite simple. It is
required to adjust the four adjusting screws in upper and lower

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section. Cares should be taken not to adjust these crews too hard.

1.3.4 During fabrication of odd shaped frames, no slipping was observed

on driven mechanism, but the sounds of clicks were heard and the
aluminum bar was found to be incapable of moving forward. It is not
caused by failure of step-by-step elements and the failure might be
caused by cutter head elements or bending elements.

1.3.5 In addition, slackness in anchor screws for gapless complex

transmission gear may also cause slipping. Under such
circumstances, dimensions of the frame might be affected during
adapting or back motion of the material feeding operation.

1.3.6 Contamination in conveyor belt.

1.3.7 Intolerate transmission sizes were usually caused by improper

adjustment of “feeding system compensating factor” and it would be
necessary to reset these parameters.
1.4 Material cutting elements

1.4.1 If the material can’t be cut or can’t be cut thoroughly, it is necessary

to check if the cutting movement can cooperate accurately with the
movement of motor. If not the cooperation, the problem might be
caused by the large quantities of aluminum chips contained in the
clearance of Saw blades. Cares should be taken that cutting times
are related to the aluminum bar width and it was required to set
accurate aluminum bar width.

1.4.2 If the saw blade make significant noises while difficulties was found in
cutting of aluminum bar, it is necessary to check status of the saw
blades. All loose blades should be tightened. Cares should be taken
during tightening to position the s aw blade in the right place.

1.4.3 Saw blade should be lubricated in suitable time if necessary.

1.5 Cutter head seat element

1.5.1 Adjustment of cutter head seat is quite complex but extremely

important. Adjustment of these elements may have direct impact over
quality of final aluminum frame products.

Care Users are suggested NOT to conduct milling operations on alloy

bending cutter head since the processing will not be

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reversible.

1.5.2 If the cutter head was replaced or bending of aluminum frame was not
satisfactory, it would be necessary to adjust position of the cutter
head to determine the optimal bending effect.

Note: All aluminum chips on the equipment should be removed by

blowtorch by the end of each shift (Figure).

1.5.3 Machine oil should be charged weekly in moving parts to provide

lubrication.

1.6 Bending elements

1.6.1 Correct position of the starting point of bending

arm should be checked during starting of
equipment every time. Otherwise suitable
counter measures should be taken in timely
manner. (Figure)
1.6.2 Worn Servo actuated suit for bending arm
(hexagonus nylon rope) should be replaced if it
loss 1.5mm in thickness. zero limit

1.6.3 Machine oil should be charged weekly in main bending shaft to provide
lubrication.

1.7 Pneumatic circuit

1.7.1 If the equipment was out of use for over a month, mobility of all
pneumatic elements should be inspected manually before re-start.

1.7.2 Gas supply route should be inspected in timely manner when obvious
gas leakage can be observed to determine exact position of escape
and eliminate potential escapes.

1.7.3 Level of lubricant in water and oil separator should be checked

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monthly. As soon as the level has gone beyond minimum limit,
corresponding lubricants specified in the manual should be added
into the separator.

1.8 electric circuits

1.8.1 Voltage of power supply should be measured during peak and trough
period of electricity consumption respectively every week. Voltage of
power supply should be within acceptable range of 200~250V.

1.8.2 All electric connections should be checked monthly to eliminate

unsecured connectors;

1.8.3 Equipment grounding conditions should be checked monthly;

1.8.4 Dusts accumulated on electric elements should be removed in timely

manner to eliminate potential shortcut or unsatisfactory connections.

1.9 equipment body and casing

1.9.1 Dusts and stains on external surfaces of equipment should be

removed on regular bases to maintain appearance of the equipment;

1.9.2 Status of fastening piece on different components of the equipment

should be inspected on regular bases. It is necessary to restore the
accurate positions of fastening pieces that running loose.

1.9.3 Status of back panel anchor screw should be checked monthly to

make sure back panels are assembled in good shape.

1.9.4 Anchor bolts of equipment body should be checked monthly to

eliminate dislocation and hanging.

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