河北省涿州市松林店電焊機總廠網址： 電熱高強鋼筋鐓頭機是將鋼筋的頭部進行電加熱到一定溫度后進行加壓鐓頭，主要特點成型均勻、鐓頭部位鋼筋強度損失小、生產率高。整個設備結構簡單、故障率低，維修方便等特點主要適用于先張法預應力混凝土構件的生產。
電熱高強鋼筋鐓頭機是將鋼筋的頭部進行電加熱到一定溫度后進行加壓鐓頭，主要特點成型均勻、鐓頭部位鋼筋強度損失小、生產率高。整個設備結構簡單、故障率低，維修方便等特點主要適用于先張法預應力混凝土構件的生產。
BBRV Machine is designed to raise the temperature of the head of reinforced bar by electrical heating to a certain degree, and then to pressurize the heading; its characterized by uniform molding, small loss in strength of the reinforced bar at the heading, and high productivity. The equipment has simple structure, low failure rate, and is convenient to be repaired; its mainly used in the production of pre-tensioned concrete members.
一 nbsp; 主要技術參數
I.Major technical parameters
1 、電源電壓 ~380V
1.Mains voltage ~380V
2 、電機功率 5.5KW
2.Power of motor 5.5KW
3 、變壓器容量 25KVA
3.Transformer capacity 25KVA
4 、鐓鍛鋼筋直徑 Φ7.1 Phi;9 Phi;10.7 Phi;12.6
4.Heading bar diameter Φ7.1、 Φ9 、 Φ10.7 、 Φ12.6
5 、鐓鍛速度 4-6個頭/分
5.Upset speed 4-6 pieces/m
6 、**大夾緊力 50T
6.Maximum clamp force 50T
7 、**大鐓鍛力 15T
7.Maximum heading force 15T
8 、預頂壓力 1-2Mpa
8.Pre-exerting pressure 1-2Mpa
9 、夾緊壓力 12-20Mpa
9.Clamping pressure 12-20Mpa
10 、**大加熱電流 6000A
10.Maximum heat current 6000A
11 、鐓頭處鋼筋強度損失 <5%
11.Steel bar strength loss at the heading <5%
12 、設備尺寸 1250×950×1200
12.Equipment size 1250×950×1200
13 、設備重量 約1500Kg
13.Weight of equipment about 1500Kg
二、操作方法
II.Operational methods
將端頭較平整的鋼筋放入鐓頭機的夾具內，端頭頂在鐓頭的電極頭 。
Place the steel bar with a relatively smooth butt end into the jig of heading machine with the butt end propping against the electrode tip of the heading.
三 nbsp; 結構
III.Structure
本機主要由鐓頭架、機架、變壓器、液壓系統以及電氣系統組
成。
This machine is mainly composed of heading rack, chassis, transformer, hydraulic system, and electrical system.
鐓頭油缸、夾緊油缸固定在鐓頭架上，同時在鐓頭架內部安裝固定夾具、活動夾具以及活動的鐓頭電極頭。
The heading oil cylinder and clamping oil cylinder are fixed to the heading rack; meanwhile, inside the heading rack, there is stationary fixture, movable fixture and movable heading electrode tip.
變壓器的次級線圈二端分別用銅帶連接夾具和鐓頭電極頭。
Both ends of the secondary coil of transformer are connected to the fixture and heading electrode tip with ribbon copper respectively.
液壓系統主要由油缸、油泵、閥體、電磁閥組成。
The hydraulic system is mainly composed of oil cylinder, oil pump, valve body, and electromagnetic valve.
四、設備的安裝與調試
IV.Installation and debugging of equipment
1 、設備的安裝條件
設備安裝的環境條件、安裝位置、工作場地不僅要符合使用說明書中的有關規定及要求，還要滿足生產的需要，為方便用戶及保證人身**。
Installation conditions and position of equipment as well as the working site shall not only meet relevant regulations and requirements in the instructions, but also meet the requirements of production, for the convenience of users and guaranteeing users personal safety.
1 ．1三相進線電源導線導電截面積不小于25mm 2 ，零線導電截面積不小于4 mm 2 ，設備要可靠接地，地線導電截面積不小于4 mm 2 。
1.1Conduction sectional area of three-phase incoming power lead shall not be less than 25mm 2 and that of null line shall not be less than 4 mm 2 ; the equipment shall be reliably grounded, and conduction sectional area of ground lead shall not be less than 4 mm 2 .
1 ．2遠離強烈震動的設備，以防止電子元件工作失靈。
1.2It shall be far away from the equipment with sharp shaking, in case the electronic components cant work well.
1 ．3設備機座必須保證水平。
1.3Seat of the equipment must be made level.
2 ．設備的調試
2.Debugging of equipment
設備安裝完畢之后，必須進行嚴格調試，調試過程按照以下步驟進行：
After installation, the equipment must be debugged exactly as per the following procedures:
2 ．1設備安裝完備后，必須檢查設備安裝的正確性。既：油箱內是否加足液壓油；接線是否正確，電源電壓是否符合規定，各處對地的絕緣是否符合要求；油箱所添加的液壓油是否符合足夠；檢查油箱及各處密封件是否有泄露現象。同時檢查各緊固螺栓是否有松動現象，檢查行程開關是否接觸良好。
2.1After installation, inspect whether the equipment is correctly installed: whether the tank is filled adequately with hydraulic oil ; Whether the wire is correctly connected; whether the mains voltage meets the specifications and the ground insulation is qualified; whether there is enough hydraulic oil in the oil tank; whether there is leakage in the tank and sealing elements; whether the fastening bolts are tightened up and the stroke switch is well contacted.
2 ．2通電檢查
2.2Power on inspection
A ．按下“油泵啟動”按鈕，檢查電機旋轉方向是否正確。
A . Press "start the oil pump" button to check whether the motor is rotating in a correct way.
B ．檢查各閥體之間是否漏油。
B ． Inspect whether there is oil leakage between the valves.
C ．按下“油泵停止”按鈕，檢查油泵電機是否能停止。
C ． Press "stop the oil pump" button to see whether the motor can stop normally.
D ．根據所要鐓頭的鋼筋直徑更換相應的夾具。
D ． Replace corresponding jigs according to the diameter of the bar to be headed;
E ．根據所鐓頭的鋼筋直徑調整鐓頭油缸的行程，根據所要鐓頭鋼筋的厚度調整鐓頭到位行程開關的位置。
E ． Adjust the stroke of heading oil cylinder according to the diameter of the bar to be headed; adjust the position of the stroke switch according to the thickness of the bar to be headed.
五、 使用操作
V . Operations
1 、根據鐓頭鋼筋直徑大小調整好變壓器加熱電流、通電時間。
1.Adjust the heating current and power on hours of the transformer according to the diameter of the bar to be headed .
2 、根據鋼筋直徑大小調整夾具，并固定。同時調節好夾具和頂頭的距離。由鐓頭油缸后端部的調節螺栓來調整。
2.Adjust the jig and fix it according to the bar diameter; adjust the space between the jig and end using the adjustable bolt at the end of the oil cylinder.
3 、調整液壓系統壓力，夾緊和鋼筋加熱后鐓頭壓力一般為12-16Mpa。預頂壓力一般為1-2Mpa。
3.Adjust the hydraulic pressure; the heading pressure is usually 12-16Mpa after clamping and heating of the steel bar. The pre-exerting pressure is usually 1-2Mpa .
4 、操作工人將端頭較平整的鋼筋緊貼固定夾具的凹槽面，并將端頭頂在鐓頭的錘頭上。
4.The operators shall place the bar with a relatively smooth end oppressed to the groove of stationary fixture with the butt end propping against the hammerhead of the heading.
5 、腳踏一下腳踏開關，立即將腳移開腳踏開關。油缸動作夾緊、預頂鍛、加溫、加壓頂鍛等程序。
5.Step on the feet switch and then move the foot away immediately. Pay attention to the procedures including clamping of oil cylinder, pre-heading, heating, pressurized heading etc.
6 、待程序進行完成以前，限位行程開關動作或程序時間結束后，機械、電氣兩部分均恢復初始狀態。
6.After the action of lead limit switch or the program time has been finished before the procedures are completed, the mechanical and electrical parts will return to the initial state.
7 、取出鐓好頭鋼筋，重新放入鋼筋進行下一次鐓頭。
7.Take out the steel bar that has been headed and feed in another one.
六、 注意事項
VI.Notice
1 、在使用過程中要掌握溫度。不可溫度太低而冷鐓，鋼筋端頭和被夾持部位生銹使鋼筋導電性能不好，也屬于冷鐓。需立即停止，除銹重鐓。
1.Pay attention to the temperature during operation. Too low temperature will result in cold heading; rustiness of the bar end and the part to be held can weaken the conductibility of the bar which will also cause cold heading; under such circumstances, stop heading immediately, descale the bar and head it again.
2 、未夾鋼筋，切不可空載鐓頭，以免損壞夾具及加熱變壓器。
2.Do not run the heading machine when there is no steel bar in case the jig and heating transformer are damaged.
3 、鐓頭鋼筋直徑必須和夾具直徑符合，才可放入夾具，否則損壞夾具。
3.Diameter of the steel bar to be headed shall be in compliance with that of the jig, in case the jig is damaged.
4 、設定通電時間及溫度，必須有專人管理，不準隨意更改，以免造成機械損傷或鐓頭溫度較低、**。
4.Set the power on hour and temperature; appoint a special person to take charge of it and do not change the temperature and hour randomly to avoid mechanical damage and too low or high temperature of the heading.
5 、待鐓頭鋼筋端頭嚴重不平不可鐓頭，以免造成溫度不均鐓頭偏向一邊。
5.Steel bar with seriously uneven end shall not be headed in case the temperature is uneven and the heading sways.
6 、溢流閥、節流閥不可隨意調節，以免造成電動機燒壞和所設定程序不配合。
6.The overflow valve and throttle valve cant be adjusted randomly in case the motor is burnt and the programs set are not suitable.
7 、應調整好限位行程開關，使每一次鐓頭都是于限位開關動作而結束頂鍛加壓，從而確保了每次鋼筋鐓頭厚度。
7.Adjust the lead limit switch so that pressurization of heading each time will be finished when the limit switch actions, thereby guaranteeing the heading thickness of the steel bar each time.
七、 液壓原理
VII.Hydraulic principle
鐓頭機中的夾緊、預頂、加壓頂、頂回程、夾具松開采用液壓控制系統。
Hydraulic control system is used in clamping, pre-heading, pressurized-heading, heading return stroke, and looseness of jig of the heading machine.
1 、通過箱蓋上的濾油器進行加油，使加入油箱的油保持清潔，加油至油位線，液壓油選用 N46 號。
1.Add oil through the oil cleaner on the tank cap to keep the oil clean; add oil to the oil level; choose N46 hydraulic oil.
2 、油泵電機起動，確認油泵電機運轉方向與實際指向一致。
2.Start up the motor to make sure the rotational direction of the motor is in compliance with the practical direction.
3 、設定好鐓頭參數，踏腳踏開關，使鐓頭機處于鐓頭狀態。調整好壓力，夾緊、頂鍛、加壓壓力一般為 12-20Mpa 。調整由靠閥座內側溢流閥 YF-B10H3-S<17> 所獲得。壓力由閥座外側的 0-40Mpa 壓力表 <11> 顯示。預頂壓力是由裝在閥座外側的減壓閥 JF-B10H3-S<15> 來調整，一般壓力為 1-2Mpa ，大小由閥座內側壓力表 <20> 顯示。調整單向節流閥 Z2FS6<13> 可獲得不同的鐓鍛速度。
3.Set the heading parameters, and step on the feet switch to run the heading machine . Adjust the pressure, clamping, and heading, and the pressurized pressure is usually 12-20Mpa. Adjust it by using the overflow valve YF-B10H3-S<17> at the inner side of the valve seat. The pressure will be shown on the 0-40Mpa pressure gauge <11> outside the valve seat. The pre-exerting pressure is adjusted by the relief valve JF-B10H3-S<15> outside the valve seat; generally, its pressure is 1-2Mpa, which will be shown on the pressure gauge <20> in the inner side of the valve seat. Different upset speed can be acquired by adjusting the one-way throttle valve Z2FS6<13>.
電磁換向閥 4WE6D50<8> 電磁鐵得電控制夾具油缸夾緊，失電后由電磁換向閥 4WE10D20<9> 電磁鐵得電，放松，斷電一直松開。
Power-on of the electromagnetic directional valve 4WE6D50<8> electromagnet can control the jig and oil cylinder to be clamped; after power-off, the electromagnet of electromagnetic directional valve 4WE10D20<9> will keep on loosening.
電磁換向閥 4WE10E20<14> 電磁鐵得失電分別控制鐓頭油缸預頂和鐓頭回程動作。加壓頂鍛由電磁換向閥 4WE6EA50<12> 得電來完成。
Power-on and power-off of the electromagnetic directional valve 4WE10E20<14> electromagnet can control the action of heading oil cylinder pre-heading and heading return stroke respectively. Pressurized heading will be finished by power-on of electromagnetic directional valve 4WE6EA50<12>.
為了保證液壓工作可靠，務必每年更換一次液壓濾油器內濾芯、液壓油，濾芯規格按照濾油器型號選配。
In order to make sure the hydraulic pressure system can work well, the filter element and hydraulic oil inside the hydraulic filter shall be replaced once a year and the specification of the filter element shall match with the type of oil cleaner.
八、電氣原理
VIII.Electrical principle
電源電壓 三相四線 380V 220V 50Hz
Mains voltage 3-phase & 4-wire 380V 220V 50Hz
控制電源 220V 本電路接觸器供電 220V ，其余繼
電器由 24V 開關電源供電
Control power Power supply for the contactor is 220V, and the rest current relay is supplied by 24V mains power.
主變壓器 25KVA 380V/3.16V, 3.45V, 3.8V
Main transformer 25KVA 380V/3.16V, 3.45V, 3.8V
本機除油泵外 , 其余各動作均由 PLC 控制 , 所有用于外部調節的數據均由 TP200 設定顯示單元與 PLC 通信而完成數據設定，外部的各按鈕，選擇開關及傳感器將機器的當前運作狀態及各操作信息反饋給 PLC ，由 PLC 處理輸出控制。
Except the oil pump, action of other parts is controlled by PLC; setting of the data used for external adjustment is finished by the communication between TP200 setting and display unit and PLC; external buttons, selector switch and sensor will feedback the current operation status and operating information of the machine to PLC, which is responsible for data processing and output control .
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