I.         Purpose

XCLL2 Smooth Hydraulic Pressure Powered Cutting Machine is a self-developed product with the introduction of advanced technology of Italy and Taiwan and combination of the research achievements on cutting machine by our company.

This machine can be used for the cutting of leather, plastic, nylon cloth, foam, synthesized fiber and nonmetal materials. Especially for the cutting of wide-range materials, it improves the defects of Smooth Gear Cutting Machine, and the cutting speed is 1.5 times faster than that of general ones.

II.      Features

1.      With the unification design of mechanical, electrical and liquid, it takes the advantage of simple operation, so no long-term operation train is needed (anyway, the operators shall know operation rules and process, and irregular operation is not allowed).

2.      The slide way of the main axis is set with self-lubricating bearings, so it can reduce abrasion by itself even though no lubrication oil is frequently mounted during working, thus its life can be extended.

3.      Hydraulic System is applied during operation. At the lower-limit position of the control stroke of the Limited Switch, it has a high accuracy which enhances the quality during shoemaking; at the rise position of the control pressing plate of the Time Relay, it’s equipped with emergency Rise Button which is simple, convenient and reliable. All the hydraulic components are imported.

4.      Main Mechanical Parts: main axis, draw bar and piston, all of which are made of good steel materials, so they are very durable.

5.      By using the inertia of flywheels, the dynamic part the machine can perform instantaneous cutting, thus the energy consumption during cutting is reduced accordingly.

6.      The setting and installation of cutter mould is very simple, and the high and low cutter moulds can be adjusted very easily, accurately and quickly.

III.   Main Technical Parameters

1.      Maximum Cutting Capacity: 250KN

2.      Cutting Speed: 0.2m/s

3.      Stoke Range: 10-100mm

4.      Distance from Pressing Plate to Working Station: 50-150mm

5.      Motor Power: 2.2kw

6.      Area of Working Station: 1620×500mm

7.      Dimension: 1880×700×1600mm

8.      Weight of the Whole Machine: 1250kg

9.      Power: 380V, 50HZ

10.  Volume of Oil Tank: 70L, 90L

IV.   Installation of the Machine

1.      Tie the steel wire on the hanging axis of the Pressing Plate, then move the machine to the installation site by Lifting Equipments.

2.      Clean the relevant parts with cleaning oil, and special attention shall paid to the butter mounted on the brake iron of the guide rail on both ends and sides. After removing the oilpapers from the surface of the working station, it shall do alignment check with level bar vertically and horizontally.

3.      Open the front sealing plate, and charge 46# oil into the Oil Tank: the oil charging volume shall be higher than 2/3 of the total height of the tank (for the oil filter must immerge in the oil).

4.      According to the requirements of Electrical Diagram, the machine shall be connected to 380V and 50HZ power with reliable earthing.

5.      Start the “Start-up Button” of motor.

6.      The rotation direction of the flywheel shall be in consistent with the arrowhead on the Front Sealing Plate.

7.      Cut off the power, and the machine stops running. Empty Run for two minutes and try run for half an hour with empty load.

V.     Function and Commissioning of the Control Components of the Machine (Attached Drawing 1)

1.      Limited Switch 1: the switch for controlling the falling point during cutting. While the cutting pressing plate and micro-adjusting screw 2 touch this switch, cutting will be stopped and the upper cutting pressing plate rise automatically.

2.      Micro-adjusting Firing Pin 2: it’s used for adjusting the cutting depth. Turn it in clockwise direction, the cutting force becomes smaller; whereas in counter-clockwise direction, the cutting force becomes bigger.

3.      Fixed Hand-wheel 3: turn it in counter-clockwise direction, the hand-wheel will be loosed and the firing pin seat of the setting bar can move up and down. If turn it in clockwise direction, the firing pin seat of the setting bar will be fixed.

4.      Limited Switch 4: during the falling of the pressing plate, it will touch this switch, after which differential action of hydraulic system will be finished and it starts pressurizing and cutting.

5.      Oil Cylinder 5: it enables the pressing plate to rise and fall.

6.      Supporting Roller 6: it makes the cutting plate on top, so it can be pushed forwards and backwards easily.

7.      Counter 7: one action of the machine will make the number of the counter increase by one. So based on the number, the working capacity of the machine can be evaluated accurately.

8.      Counter Option Switch 8: the working switch of the counter.

9.      Cutter Setting Switch 9: it is used for the setting of the cutter. And the setting methods will be detailed in other chapters.

10. Emergency Stop Button 10: under any condition, as long as push this button, the pressing plate will stop falling and begin to rise.

11. Limited Switch 11: the switch is for controlling the rise-height limit of the pressing. When the right winch touch this switch, the pressing plate will stop rising at once, so this switch shall be set at the end of the oil cylinder route on principle in case that the  configuration of the oil cylinder and machine will be damaged due to long adjustment of timer during the rising of the upper pressing plate.

12. Motor 12: running by using current, and driving the oil pump accordingly.

13. Oil Pump 13: pump out the hydraulic oil in the oil tank for the working of the machine.

14. Adjusting Screw 14: check the level of the machine during installation.

15. Overflow Valve A15: it’s used to set the safety pressure during cutting, when the cutting pressure exceeds the set value, this valve will overflow. So it can prevent the oil pump being damaged by overpressure. It has been set before ex-factory.

16. Solenoid Valve 16: control the rising and falling of the pressing plate.

17. Solenoid Valve 17: control the differential loop and enhance the falling speed of the pressing plate.

18. Adjusting Screw Cap 18: it’s used for adjusting the right-left parallel degree between the upper cutting pressing plate and the surface of the lower working station. When turn it in clockwise direction, the upper cutting seat will rise, and in the contrary direction, it will fall. The setting has been finished by certain authorized party, so if it needs to be readjusted, professional technicians shall be involved.

19. Fixed Screw Cap 19: it is mainly used to lock Screw Cap 18 after it being properly adjusted.

20. Motor Stop Button 20: after pushing this button, the motor will stop running and the oil pump stops supplying oil.

21. Motor Start Button 21: the motor starts running after pushing this button.

22. Power Indicator Light 22: it means that there has been input power when it lights.

23. Timer 23: it’s the timer of the upper cutting pressing plate. The longer the adjusting flow of time is, the higher the upper cutting pressing plate can rise; on the contrary, the shorter, the lower. Please note that it cannot be adjusted to be “zero”, or else the upper pressing plate will now rise, and it cannot start the next cutting accordingly.

24. Brake Iron 24: during operation, if the upper pressing plate is loose or the front and back surface are unparallel with the contact surface, you can see the adjusting screw inside after dismantling the front electrical board and back cover board of the slide rail. Please adjust the screw until the front and back surface of the pressing plate are parallel with the contact surface of the rail, so it can ensure steady rising and falling of the pressing plate.

25. Hand-operated Button 25: push this button manually, cutting stops.

VI.  Operation Instruction of the Machine (Attached Drawing 1)

1.      Setting of the Cutting Point

1)      Push the Emergency Stop Button 10, the upper cutting pressing plate shall rise to the top position; then push Hand-operated Button 25, check if the upper pressing plate will fall.

2)      Clean the surface of the cutting plate and locate the cutter in its center. (note: hard substances are not allowed to put on the cutting plate, for they will damage the cutter mould)

3)      Loose the Setting Hand-wheel 3 and make the firing pin on the setting bar fall freely, during which it shall hit Limited Switch 1 and the Micro-adjusting Firing Pin shall be adjusted to micro-adjusting status. (turn it 2~3 rounds)

4)      Turn the Setting Switch 9 of the cutter at “on” position, and then the pressing plate will fall to the position where it can touch the cutter mould.

5)      Lock the Fixed Hand-wheel 3.

6)      Adjust the Timer 23 which controls the rising of the upper pressing plate. (the indicating position of the Time Relay is about 0.8s)

7)      Turn the Setting Switch 9 of the cutter at “off” position, the upper cutting pressing plate will stop after it rises to the setting time. In order to pull out the cutting plate and change the position of the cutter mould, the set rise-height shall be the about summation of the thickness of cutter mould and materials plus 10mm.

8)      Push Hand-operated Button 25, and do try-cutting (please keep your hands away form the lower part of the upper cutting pressing plate in case of being hurt). The upper cutting pressing plate will fall and practise cutting until it touches the cutter mould which means that the Limited Switch 1 is at the falling point of cutting. At this time, a plate with thickness about 1mm shall be filled beneath the cutter mould, after which the girder starts rising until to the setting time. Check the depth of the cutter and adjust it repeatedly until the result is satisfying.

9)      Adjust the Micro-adjusting Firing Pin 2 to the perfect cutting depth.

10)Then the setting of the cutting point for cutter is finished.

2.      Cutting Steps

1)      Push Emergency Stop Button 10 to make the upper pressing plate rise to the setting limit height.

2)      Pull out the Feeding Plate and put the cutter mould on the materials, and then push in the Feeding Plate and fix the position.

3)      Push Hand-operated Button 15 and cutting starts. The upper cutting pressing plate begins to fall, but when the Micro-adjusting Firing Pin which controls the cutting point hits the Micro Switch, the plate will stop falling and start rising to the height determined by the setting time. At this time, check if all the materials are completely cut or not, if not, adjust the firing pin a little higher until it can.

4)      Pull out the Feeding Plate and change the position of the cutter mould, and then do the next cutting job. The cutter moulds shall be arranged in equation in case of leading to abrasion of the machine.

VII.              Notice During Operation

1.      During the cutter setting, it shall first loose the Setting Hand-wheel 3, or else the weight of the girder will bend the electrical spacer when the Setting Switch 9 of the cutter is changed to “on” position.

2.      During working, the cutter shall be put in the center of the upper pressing plate as possible as you can in order to avoid one-side abrasion of the machine and life-shortening accordingly.

3.      The Overflow Valve 15 fixed on the oil-way block has been well set by the factory, so please do not adjust it freely in case that it will damage hydraulic components, and the hydraulic system cannot work normally any more.

5.      During cutter changing, if they have different heights, please reset it according to the setting methods.

6.      During cutting, please keep your hands away from the cutter and filling plate. In order to keep safe operation, to touch the cutter with hands is not allowed.

7.      When the operator needs to leave the operation position, he must push the Emergency Stop Button or power off the motor in case that the machined is damaged by improper operation by others.

8.      The power of this machine adopts Three-phase and Four-line system, so the “zero” Line cannot be taken as “earth” line.

9.      This machine needs safe earthing.

10. Unqualified person is not allowed to dismantle or install the electrical and hydraulic parts.

11. It’s not allowed to work for 24 hours continuously. And the oil temperature must be under 60℃.

12. Overload use in not allowed in case the life span of the machine will be shortened due to the damages it caused.

13. This machine must be operated with both hands by one person. For the sake of safety operation, two-person operation is not allowed.

VIII.          Machine Maintenance

1.      Upper Cutting Pressing Plate: when the machine stops working for one day, please loose the Setting Hand-wheel 26 in case of damaging relevant parts. During operation, the cutter mould shall be put in the central area of the cutting section and the oil shall be mounted on the brake iron one time per day.

2.      The connectors of oil pipes shall be locked tightly in case of oil leakage, and abrasion of oil pipes is not allowed during moving. For pipe dismantling, a filling block shall be put at the bottom seat of the pressing plate. Make the pressing plate fall out of the filling block in case that large amount of circulating oil will be leaked out.

3.      Only under no-pressure condition and when the motor completely stops (flywheel stops rotating), the components of the hydraulic system can be dismantled.

4.      The hydraulic oil in the oil tank must be replaced after about 2400 hours use, especially for the new machine, it’s better to change the oil after about 2000 hours use for the first time. 500 hours after the installation of the machine or oil changing, it shall clean the oil filtering net. Or when you feel the noise of the oil pump too louder, it shall be cleaned. For each time of hydraulic oil changing, it shall clean the oil tank thoroughly. The level of hydraulic oil shall be at least 300mm higher than the filtering net, but anyway, it shall be about 30mm lower than the surface of the oil tank.

5.      Keep the electrical parts clean and dry any time.

6.      Clean the machine before leaving work everyday, and check if the screw is loose or not to make sure it’s locked.

7.      When the machine is not running, power off all possible motors.

8.      For all the slide positions, oil shall be mounted one time per week.

IX.  Common Faults and Solution Methods