Spiro 1600 Tubeformer

Spiro 1600 Tubeformer 

Forming head

Support arm

Key

Base for forming head

Adjustment handle for support arm

Clamping roller valve handle

Electrical control cabinet

Cutter motor

Cutter gear box

Cutter axle

Cutter saw blade

Adjusting screw for cutting depth

Adjusting valve to cutter

Guide plates

Low-speed selector

Low-speed scar texture

High-speed start button

Start switch hydraulic pump

Start switch lubricant pump

Main switch

Discharge control button

Cutter start button

Indicator lamp

Automatic relay switch

Clutching roller pressure valve

Drive roller pressure valve

Clutching roller pressure gauge

Drive roller pressure gauge

Tool board

Cut balance scale

Scale indicator

Upper drive roller

Fastening screw for lubricating unit

Base for temperature regulation

Lubricating unit

Oil cooler

Center and tack bar

Oil motor

Inspection door oil tank

Rib

Oil tank filler up

Oil level eye

Hydraulic pump motor

Oil hoses for discharging cylinder

Oil hoses for cutter cylinder

Spring

Fastening bolts for cutter Draw. No. 811

Microswitch for stop of cutter

Adjusting handle for cutter angle

Base plate for corrugating unit

Flange roller arrangement

Adjusting screw for hanging hinges

Guide plate locking handle

Bearing cap upper drive roller

Bearing cap lower drive roller

Roller housing

Lubricating device

Hydraulic cylinder for drive reverser

Adjusting screw for angle of roller Ø

Discharge serrated valve

Cutter solenoid valve

Plow valve

Oil flow control valve

Oil tank

Thermostat

2000 Minimum 1210 1015 0 0 IN RECEIVING R/WP 0 OPTIONAL TABLE 

2065 935 1555 750 The above data represents the surface of the machine and shows that the machine can perform at a maximum speed of 1100 revolutions per minute. The purpose of this data is to demonstrate the machine's capabilities and provide instructions on its usage

RUN-OFF TABLE ASSEMBLY Each run-off table has two end-frames with bearings for two adjustable cylindrical supporting rolls. Cogwheel segments maintain equal distance between the support rolls and handle adjustments are made to adjust the distance between the rolls for every change in tube diameter. The support rolls are mounted in both end-frames which are bolted together by distance bars. Two upper bars have taps for connecting the receiving ramp. To assemble the run-off table, first, put the support rolls into their bearings, then fit the four frame bars and screw it so that the cog-segments are correctly meshed, and both support rolls have the same distance from the centerline of the table. A T-shaped iron is fixed to the vertical taps. This T-iron is the base for the movable remote control switch, which is a sensitive proximity switch. The switch holder can be slid along the T-iron and fastened with a set screw. The run-off tables are connected together by joining the two T-irons. On each table, there are two discharge arms which lift the tubes up from the support rolls when the cutting operation is finished. The discharge arms are linked together with a parallel rod, and between the first and second table, these rods are connected by a coupling. To adjust the height of the tables, each end-frame is placed on floor plates, which are fastened to the floor by expansion bolts. The end-frames are fastened to the floor plates by bolts, which are also height adjustment screws. When the height of the table is determined, these bolts are fastened by tightening the nuts and keeping the tables in position in all directions. The first end-frame of table no 1 is equipped with a hydraulic cylinder for engaging the discharge arms. Two flexible oil hoses from the machine lead to the cylinder and have to be connected when the assembly of the run-off table is finished.

FORM ROLL UNIT Make sure that the correct form roll unit is mounted in the machine. The unit is fastened with two screws to the base in the roller housing. Strip thickness tolerance and strip width are given in inches and millimeters, and they include the maximum tolerance. The figure is showing a form roll unit with 3 sets of form rollers. The unit has one set of guide rollers which also serve as a lubricating station. The end rollers are made of hardened steel and are interchangeable. The guide rollers are fixed in their position by a set screw. It is possible to adjust the guide rollers sideways to get the right measurements of the flange and channel of the strip.

GUIDE PLATES The machine is equipped with four standard guide plates: upper and lower front guide plates and upper and lower rear guide plates. There is a space between the front and rear plates where it is possible to cut the strip material when changing from one tube diameter to another. A special set of sheet inlays must be fixed between them to allow the strip to pass freely between the upper and lower guide plates when the plates are pressed together by means of the guide plate lock and the support arm. The inlays should always be thicker than the strip material used. The guide plate lock, an eccentric locking device, is fitted with two adjustable set screws, depending on the thicknesses of the sheet inlays.

Thickness of strip material (in MM) Inlays Thickness of 25 22 20 18 16 Gauge 0.5 0.7 0.9 1.25 1.65 Between upper and lower guide plates 0.7 1.0 1.25 1.5 2.0 Underneath lower guide plates 1.25 1.0 0.7 0.5 0.0

When inlays are also used underneath the lower guide plates, it is possible to adjust the strip material tangential to the upper drive roller.

FORMING HEAD The forming head is located on the base and clamped in position by means of a key or lockpiece. Before fastening the key with screws, be sure that the clinching roller can move freely up and down hydraulically without touching the sides of the opening in the footplate of the forming head. Before inserting the forming head, ensure that the footplate of the forming head is clean and free from any metal particles.

DRIVE ROLLERS The machine has two rollers, one upper and one lower drive roller. The upper drive roller has a knurled surface and is the real drive roller, whereas the lower drive roller has a smooth surface and works as a support roller. The hydraulic pressure on the drive rollers can be adjusted by the drive roller pressure valve on the control panel. The pressure is indicated by a gauge on the panel.

DECOILER The machine can be delivered with either a vertical or horizontal decoiler. The vertical decoiler holds two coils of strip ton each for continuous feeding into the machine. A lockpin on the top of the rotating column prevents the decoiler from moving when the machine is pulling the strip. This decoiler is equipped with a shock absorber to ensure smooth uncoiling. The horizontal decoiler consists of a base with four wheels and a circular steel disc of 1000 mm diameter on which the coils are placed. With this decoiler, the strip has to be turned 900 before it enters the form roll unit, and the machine roller housing is equipped with a special set of guide rollers for this purpose. The horizontal decoiler is equipped with a strip guide roll that is connected to a brake. The decoilers can be delivered with different hub diameters to fit the various inner diameters of the strip coils.

CONTROL PANEL The control panel includes a speed selector, low speed start button, high-speed start button, start switch for the hydraulic pump, start switch for the lubricant pump, main switch, discharge control button, cutter start button, and automatic restart switch. Before inserting the leading end of the strip into the machine, the strip edges have to be

Cutting the Tube:

To trim the edge of the tube, press the start push button 22 on the panel to bring the cutter into operation. The cutter axle with the saw blade will rise and penetrate the tube. Adjust the rising speed of the saw blade by using the small throttle valve 13 located at the end of the hydraulic cylinder of the cutter. This valve controls and regulates the oil flow to the cutter cylinder, ensuring that the saw blade does not raise too fast against the tube wall, which would dent the tube. The valve regulates the oil flow in one direction only, and the return action of the saw blade is always fast.

When the saw blade has penetrated the tube, the drive rollers will automatically start to rotate at a low speed via the adjustable time relay located in the center of the small contactor blocks in the electrical cabinet. The drive rollers will resume their drive on the strip material, and the tube forming operation will continue, causing the tube to move and carry the saw blade for a distance corresponding to a complete rotation of the tube. Then, a final severing of the tube will be completed.

The saw blade will touch the switch 48 and move back to a position clear of the tube and ready for new action. At the same time, the switch will also stop the low speed.

To preset the speed of the machine when cutting the tube, turn the speed selector knob 15 to a position that gives the best cutting speed. This speed varies depending on the strip thickness and the diameter of the tube. For very big diameters such as 1250 mm, the lower setting is especially necessary during the cutting through the lockseam. After cutting through the seam, the speed can be increased a little by turning the knob 15. For thinner gauges, the cutting speed can be set from 2 to 5.

If the automatic restart switch 24 on the panel is set to position 1, the discharge mechanism on the run-off table will be brought into action simultaneously as the saw blade returns. The hydraulic discharge cylinder will lift the tube slightly and cause it to roll onto the receiving ramp. Simultaneously, the discharge arms will return to their downward position, and the machine will automatically start on high speed. This automatic start of the high speed can be delayed from 0 to 30 seconds by means of the adjustable time relay located on the right side of the small contactor blocks in the electrical cabinet. The time for the return of the discharge arms can be delayed by means of the adjustable time relay located on the left side of the contactor block.

If the automatic restart switch 24 is set to position 0, the discharge mechanism can be operated from the control panel by the push button 21. The machine will also have to be started again by push button 17.

The length of the tube is determined by adjusting the remote control switch along the run-off table. This movable remote switch is a sensitive proximity switch that has a sensing head to detect electrically conductive materials up to 20 mm away. When the leading end of the tube passes the sensitive zone of the switch, a trigger mechanism will start the cutter operation, the drive roller will stop, and the cutter will start.

Saw Blade:

The saw blade must be sharp at all times. When running, it can be sharpened on the machine by applying a fine emery wheel to the friction blade. If the blade leaves a burr on one side of the tube, the blade has not been sharpened square across the teeth. For ferrous metal, the friction blade is Black Decker, Cat. No. 39560, U-1908 8 blade. When running aluminum or other non-ferrous metals, use the saw tooth blade Gunther & Co Tit

To ensure optimal performance of the machine, it is important to regularly lubricate and clean certain parts. Using guide rollers instead of guide plates can prevent oil buildup, as the strip will be oiled just before entering the form rollers. In all cases, cleaning the form rollers is crucial. The cutter gear box must also be regularly checked and filled with specified oil up to the inspection screw. When working with non-ferrous materials, the saw blade should be lubricated with motor oil to prevent material buildup. The gear box between the oil motor and the drive rollers of the 700 machine should be regularly inspected through the plexi-glass cover on top of the gear box to prevent excessive wear. The lubricating chart should be used to determine the proper oil for each machine part.

When changing from one tube diameter to another, the forming head must be changed. First, remove the short length of tubing in the forming head on the machine after the cutting-off operation. Then, use a specially provided ring pull ring to support the wall of the tube and rotate it out of the head. For large tube diameters, tubes made from light gauges may be pressed inward of the forming head. Carefully deform the tube end to rotate it out of the forming head. Alternatively, force the flange of the strip to jump out of the channel by slightly turning the roller housing 56, allowing the tube end to be lifted out from the head. During this action, run the machine at a slow speed and slack back the folding fingers to allow the strip to pass freely.

When running heavy gauges such as 18-16 MM, care must be taken to form the flange and channel to the correct size. The measurements for the different strip thicknesses are pointed out on page 3. Especially for form roll unit, it is very important that the measurement of the flange A is set to MM .335 inches. When the flange is too high, it is nearly impossible to press the lockseam together. If the drive roller and clinching roller pressure in such cases are increased to compensate for the lack of compression in the lockseam, the result will be that the resistance in the clinching operation will increase, and the drive roller will slip and lose its pushing effect. If the drive roller does not slip, the oil pressure in the oil motor system will increase until the oil pressure reaches the pressure limit, which is set to 150 Ato. The relief valve will open, and the rotation of the oil motor stops. In that case, the pressure on the clinching roller must be released, and the tube rotated out of the forming head. When checking and adjusting the flange size of the strip in form roll unit No. 5, the distance-bar with the two guiding ball bearings must be loosened and adjusted sideways. Run a short length of strip after adjusting the distance bar and let it pass without entering the forming head. After checking the flange size again, the strip is cut and guided into the forming head. If the tube is still difficult to run, jerking and slipping might occur. This is mainly when running at a slow speed and during the cutting operation. Poor strip quality might be the reason; the strip is too hard and difficult to bend. Very small differences in the hardness will give big differences in respect to the required power, especially when forming strip sections with thicknesses above MM 18. The diagram will give an indication of the relation between the strip thickness and the required power for forming the strip thickness sections. The oil motor does not start to rotate when the hydraulic is switched on. This is normally due to cold or thick oil in the pilot valve. When the electric motor with hydraulic pump has been switched on and been running for a short while, the oil motor will start to rotate. The oil motor starts to rotate with a jerk. No soft start or slow acceleration speed. The acceleration speed can be regulated by means of the regulating screw on the pilot valve. Turn the screw very slightly inward if you want a slow acceleration speed, outward if you want quicker acceleration. Use a 3 MM unbrako key. Oil pressure does not rise. 1. The hydrostat in the relief and unloading valve has jammed, probably through dirt. Check, by removing the end cover on the right-hand side of the valve, the piston is pushed out by the spring. The throttle is screwed in too far. Open slightly. Pressure fluctuations. Screw in the throttle to damp out the fluctuations. Do not screw in too far. Normally 3/4 - 1 turn open. The relief valve is adjusted to open at a pressure of 150 Ato. Do not make any new adjustments of the relief valve. One complete turn of the screw corresponds to a pressure increase of approx. 100 Ato. Faults in the cutter and discharge valves. If the cutter and discharge cylinders do not move when energized, this is always due to jamming of the piston in the valve. Usually, there is a little particle causing all the trouble. On the end of the solenoid, there is a little hole, where it is possible to push the piston in one direction. When pushing, it is possible to loosen the particle. If this pushing does not help, the valve must be unscrewed, and the end