Steel cylinder test pressure loading and unloading machine
¡¡¡¡¡¡A steel bottle type of test pressure loading and unloading machine in model of ZL-1/22.5-III is a third decade of improved test pressure device. Compared with early products, its main character is taking a pneumatic clamping device and a pneumatic facility for returning water to restored position (if the user want to use a manual way for claming, it can be order to make). Overcoming the every kind of the abuses in electronic way for returning water to restored position, our products have the higher equipment reliability and a more convenience for operation. In an old way, the returning water angle and the restored position are controlled by a journey switch. Due to the inertia moment will be changed as the loading change after the motor stop, the returning water angle and the restored position are very difficult to determine and the reliability of the journey switch is low, so it is very easy to take place an accident. However the determining the returning water angle and the restored position in a pneumatic device is determined by the stroke of the cylinder, so the returning water angle is stable and the restored position is reliable. In addition, the toppling speed of the steel bottle can be adjusted in no class by the anechoic throttle on the manual controlled valves of ¡°returning water¡± and ¡°restoring position¡±, which is easy and reliable.
¡¡¡¡¡¡The steel bottle test pressure loading machine is composed of two parts: 1. a loading bottle valve device and a returning water device; 2. an electric test pressure pump and a measuring cylinder. If the user does not need the test pressure pump part, this equipment will be changed into a bottle loading and returning water machine. The user can only use the function in the bottle loading and the returning water.
¡¡¡¡¡¡The steel bottle test pressure loading machine is for the test in the resist pressure, the volume distortion and the loading & unloading the bottle valve on the steel bottle (oxygen, hydrogen, nitrogen and CO2 etc.) by ¡°a steel bottle safety monitor procedure¡±, according to the requirements for the steel bottle inspection and the bottle valve loading & unloading in the steel bottle manufacturer, the steel bottle inspection and the filling gas station. The machine gathers machinery, electricity and pneumatics and can realize the following three functions:
¡¡¡¡¡¡a. The loading & unloading the bottle valve£»
¡¡¡¡¡¡b. The water pressure intensity test, the volume distortion measure & test£»
¡¡¡¡¡¡c. The turning over for water fall.
¡¡¡¡¡¡The equipment structure is fastness, the performance is reliable, the technology is advanced, the operation is easy, which is a necessary use device in the steel bottle manufacturer, the steel bottle inspection and the filling gas station.
¡¡¡¡¡¡1. The rational water test pressure P1=22.5MPa
¡¡¡¡¡¡2. The valve automatic control wrest moment on the spindle M1=300N¡¤m
¡¡¡¡¡¡3. The maximal wrest moment on the spindle gas valve M2=450N¡¤m
¡¡¡¡¡¡4. The returning water angle R=145O
¡¡¡¡¡¡5. The drive motor
¡¡¡¡¡¡ The model Y90S-4
¡¡¡¡¡¡ The power 1.1KW
¡¡¡¡¡¡ The rotation speed 1390r/min
¡¡¡¡¡¡6. The power source£º 380V/50HZ
¡¡¡¡¡¡7. The gas source£º P=0.7-0.8Mpa£¨a safety gas£©
¡¡¡¡¡¡8. The top & bottom stroke of the spindle S1=530mm
¡¡¡¡¡¡9. The stroke of the steel bottle clamping machine S2=100mm
¡¡¡¡¡¡10. The outer size£º£¨length¡Áwidth¡Áheight£©
a. The main body size£º1000¡Á600¡Á3000
¡¡¡¡¡¡¡¡¡¡¡¡¡¡b. The electric operation station£º600¡Á450¡Á1150
£¨The electric box without the test pressure pump is installed on the main body of the equipment£©
¡¡¡¡¡¡¡¡¡¡¡¡¡¡c. The electric test pressure pump£º 655¡Á480¡Á1055
11. The weight£¨the main body£©£º750Kg
12. The specification of the measured steel bottle£ºThe diameter ¦µ210¡ª¦µ220
The height H=1200-1600
¢ó. The introduction for the structure principle
¡¡¡¡¡¡The steel bottle test pressure loading machine is composed of the bottle valve loading & unloading device, the returning water device, the electric operation station and the electric test pressure pump (if there is no a test pressure pump, it can only be used as a bottle valve loading & unloading machine and a returning water machine, so this manual is used as a use instruction manual for the bottle valve loading & unloading machine). The machine main body is installed on a bracket, which mainly is composed of the following parts:
1. The spindle £¨The clamp header of the loading & unloading valve is connected with a gimbal£©
¡¡¡¡The motor is rotated by a belt drive in reducing speed to lead the clamp header to realize the functions of the loading valve and the unloading valve. The spindle can be moved toward up or down (by the hand pushing) and be balanced by the balance block and can stop at any position in the moving scale.
2. The clamp organ
¡¡¡¡¡¡It takes the compressed gas as a power to push the piston in the cylinder to do a to-and-fro movement to realize the clamping or the unclenching for the steel bottle.
3. The gas returning water organ
¡¡¡¡¡¡It takes the compressed gas £¨0.7-0.8Mpa£©as a power to push the cylinder to drive the tooth bar and the tooth bar drive the gear to rotate in 145¦Ï. Because the tooth bar connects with the clamp organ of the steel bottle, which will make the steel bottle rotate 145¦Ïto realize the returning water action.
4. The bottle valve loading & unloading clamp header and the test pressure mouth£¨can be replaced with bottle valve£©
¡¡¡¡¡¡The clamp header and the spindle are connected with the gimbal for the loading & unloading bottle valve and the water pressure test of the steel bottle.
5. By means of the electric control buttons and the pneumatic switches on the electric operation station, you can realize the above every operation.
¢ô. The installation
1. The equipment body and the foundation are connected with the foot bolts and the pressing plates, which level <1©L/m.
2. Connect the compressed air pipeline and ask the pipe arrangement to be in order and no leakage.
3. The operation station and the electric test pressure pump should be located at near the equipment body and connected the gas source and the power source by the requirements.
¢õ. The usage instruction
1. The preparation work
a. The gas source£º
¡¡¡¡¡¡To assure the gas pressure in 0.7-0.8Mpa, except the air compressing pump, you can get the compressed gas (nitrogen is the best) by a decompression valve. Adjust the pressure in0.7-0.8Mpa£¨one bottle of oxygen in 12Mpa can supply the cylinder in the equipment to work about 300 times£©.
b. The power source£º
¡¡¡¡The equipment uses a power source of 380V/50HZ in three phases. Assure the drive motor to be connected in the phrase according to the requirements and the control station be earthed (push down the button of ¡°the increasing valve¡± and the spindle will rotate in clock direction).
c. Adjust the limited pressure connection point on the pressure meter on the test pressure pump at 22.5Mpa.
d. Put the steel bottle into the clamp organ.
2. The unloading valve operation
a. Put the empty bottle into the clamp organ and pull down the spindle and cover the unloading valve clamp header on the bottle valve.
b. Operate the ¡°clamp¡± switch to clamp the steel bottle (the pneumatic switch and the ¡°loosing¡± switch are the pneumatic elements, the difference is the pulling bar position).
c. Push down the ¡°unloading valve¡± button and turn down the bottle valve, then push down the ¡°stop¡± button and take down the bottle valve.
d. Operate the ¡°loosing¡± button (the pneumatic switch) and take out the empty bottle.
3. The loading valve operation
a. Put the empty bottle needed to install the bottle valve into the clamp organ and tighten the valve by hand and cover the clamp header on the bottle valve.
b. Operate the ¡°clamp¡± switch (the pneumatic switch) to clamp the steel bottle.
c. Put down the ¡°loading valve¡± button. When the wrest moment is increased at 300N¡¤m (the motor current will rise to 2.9A-3.2A), the automatic control wrest moment device (the motor synthetic protector) will cut down the motor power source and the loading valve is finished.
¡¡¡¡¡¡The wrest moment of the loading valve in the machine is controlled by an automatic device, which principle is : when the wrest moment of the bottle valve increases, the motor current will be increased; when the wrest moment reaches at a certain value£¨300N¡¤m£©, the motor current just reaches at the value making the automatic control wrest moment device (the motor synthetic protector) act. (The current action value of the protector and the rising motor current value can be adjusted together to realize the automatic control for the wrest moment. So you see, the user can make a small adjustment for the current value of the overflow protection on the protector to adjust the tighten wrest moment on the bottle valve).
4. The operation for the resist pressure test on the steel bottle£º
a. After fill up steel bottle with water, wait for over two hours, then put the bottle into the clamp organ and install the test pressure mouth (can be replaced with a new valve). According to the operation method for loading the valve, tighten the test pressure header, then loose the clamp organ and connect the outlet of the test pressure pump and the test pressure header perfectly.
b. Start the test pressure pump until the pressure is increased to 22.5Mpa£¬then push down the ¡°stop¡± button£¨the test pressure pump with an electric connection point pressure meter will stop£© and keep the pressure for five minutes. Observe if the steel bottle is conformity and begin to reduce the pressure. Clamp the steel bottle again for unloading the test pressure mouth and finish the test.
¡¡¡¡¡¡Note: if the user needs to test the volume distortion of the steel bottle, the operator must pass the train by the administration department and go to job with the certification. The operation method is not described in the manual.
5. The returning water operation
a. Push the spindle to the most top position and operate the handle valve to raise the steel bottle.
b. Operate the pneumatic switch to clamp the steel bottle, then operate the handle pulling valve to put down the bottom cylinder and operate the ¡°returning water¡± switch(the handle pulling valve-- the pneumatic switch ) to make the steel bottle turn over 145¡ãbottle mouth for pull water out. You can insert a leading air pipe into the bottle mouth to raise the pulling water speed up.
c. After pulling water out (it is the best for drying the bottle by a heating air), then operate the ¡°restoring position¡± switch (the pneumatic switch and the ¡°returning water¡± switch are the pneumatic elements, the difference is the pulling bar position) to make the steel bottle turn 145¡ã to restore the position.
In order to make the operators hold the operation in the equipment skillfully, before the normal use, it can be test running by above operation steps. After the empty running is correct, it can be put into the running.
¡¡¡¡¡¡The equipment should be operated by the special persons with the knowledge in the electric, the gas circuit (the hydraulic) and the machinery and pass the test. The persons without the train are prohibited to operate the equipment.
¢ö. The maintenance
1. The gear, the tooth bar, the spindle and the bears need to put the lubricating grease in a fixed term.
2. If the belt is loosed or sliding, it should be adjusted the distance or replaced a new one.
3. It is necessary check the circuit system in a fixed term to keep a good earth.
4. It is necessary check the gas pipe and the gas route system in a fixed term to remove the leakage point on time to keep every operation to be carried out smoothly.
5. The test pressure pump should be maintained one time every year and the main body of the equipment should be maintained one time every three years.