As a manufacturer and supplier of octagonal tube roll forming machines, KINGREAL Roll Former not only provides customers with octagonal pipe roll forming machine, but also offers complete one-stop solutions for roller shutter door production and installation, comprehensively meeting customer needs.
Proper and meticulous daily maintenance and troubleshooting of the octagonal tube roll forming machine are crucial for ensuring long-term stable operation, extending equipment lifespan, and maintaining consistent finished product quality.
Therefore, KINGREAL Roll Former will break down the core maintenance points of the octagonal pipe roll forming machine in detail and share practical maintenance tips to help manufacturing enterprises standardize equipment operation and maintenance, ensuring the efficient and stable operation of the octagonal tube roll forming machine.
Maintenance of Octagonal Pipe Roll Forming Machine
(1) Roll Residue Cleaning
During the production and processing of octagonal tubes, the galvanized layer on the surface of the raw material will generate a large amount of zinc dross and oxide residue during forming, extrusion, and friction. This residue accumulates over time on the surface of the rollers, forming grooves, and gaps of the octagonal tube roll forming machine. If not cleaned promptly, residue will continue to press against the tube surface, causing quality defects such as scratches, dents, and dimensional deviations in the octagonal tube. It will also wear down the working surface of the rolls, shortening their lifespan and affecting the overall forming stability of the octagonal pipe roll forming machine. Currently, the most common and safest cleaning method in the industry is mechanical cleaning.
When cleaning residue from the rolls of the octagonal tube roll forming machine, appropriate cleaning tools must be selected, preferably high-quality nylon brushes or specialized metal scrapers. For light residue buildup, the roll surface can be repeatedly wiped with a handheld nylon brush to thoroughly remove loose galvanized residue and dust. For firmly adhered hardened zinc slag, a metal scraper can be used to gently scrape it off. During the operation, the force must be strictly controlled, and the operation must be performed at a uniform speed, conforming to the curvature of the roll surface. After cleaning, the roll gaps must be cleaned again with a brush to ensure no residual impurities remain, guaranteeing a smooth and clean working surface for the octagonal pipe roll forming machine rolls, providing a precise guarantee for subsequent octagonal tube forming processing.
(2) Standard Hydraulic Oil Replacement
First, before replacing the hydraulic oil in the octagonal tube roll forming machine, the hydraulic cylinders must be thoroughly disassembled and cleaned to remove all residual old oil, sludge, and impurities. It is important to note that simply cleaning the cylinders is insufficient for a complete oil change. A significant amount of old oil will remain in the main and branch hydraulic circuits of the octagonal pipe roll forming machine. Adding new oil directly will cause the old and new oils to mix, accelerating oil deterioration and reducing lubrication and transmission efficiency. Therefore, after cleaning the cylinders and adding new oil, the main hydraulic circuit pipe must be disconnected. The octagonal tube roll forming machine should be started and kept running at low speed under no-load. The oil pump should be continuously operated, and each hydraulic transmission component of the equipment should be operated sequentially. The fluidity of the new oil will help to flush out the old oil and impurities from the circuits.
After completing the inspection of all oil circuits and confirming that there is no residual old oil or blockage, new hydraulic oil should be added to the hydraulic oil tank of the octagonal pipe roll forming machine, filling it to the standard oil level range marked on the equipment. This completes the oil change operation.
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(3) Standard Chain Lubrication
Before lubricating the chain of the octagonal tube roll forming machine, it is essential to use a brush and high-pressure air gun to clean the surface of the chain, removing dust, oil, abrasive metal particles, and other impurities. This prevents these impurities from exacerbating internal chain wear.
After cleaning, the appropriate lubricant should be selected based on the chain's operating temperature, speed, and production load. For high-temperature and heavy-load production conditions, a high-viscosity, high-temperature resistant, and wear-resistant special lubricant should be used to meet the high-intensity operation requirements of the equipment.
3.1 Manual Lubrication
Manual lubrication is suitable for maintaining the chain of the octagonal pipe roll forming machine during low-speed operation and light-load production. An oil can, special oil brush, or applicator can be used. A fixed maintenance cycle should be established, typically once per shift or once per week. During lubrication, focus on evenly applying lubricant to the core friction areas such as chain pins, bushings, rollers, and chain link gaps to ensure full lubrication coverage.
3.2 Drip Lubrication
For octagonal tube roll forming machines operating at medium speeds and undergoing routine mass production, drip lubrication is the preferred method. This provides continuous and uniform lubrication, meeting the needs of continuous production. During operation, a dedicated drip cup and device must be installed on the side of the chain, connected to the chain plates and side plate edges via a sealed oil pipe. The drip rate should be adjusted to a uniform drip rate of 4-20 drops per minute, ensuring precise lubrication into the chain gaps. As the chain of the octagonal pipe roll forming machine continues to operate, the oil can evenly penetrate to core friction areas such as pins and sleeves, forming a stable lubrication layer.
Troubleshooting Techniques of Octagonal Tube Roll Forming Machine
(1) Octagonal Tube Forming Dimensional Deviation & Surface Unevenness
First, check if the surface of the octagonal pipe roll forming machine's rollers is covered with a large amount of galvanized residue and oxide impurities. Accumulated impurities will directly compress the tube, causing forming defects. Timely cleaning will restore forming accuracy.
Second, check if the rollers are worn, misaligned, or loose. Long-term equipment vibration can easily cause the roller fixing bolts to loosen and the forming position to shift. The machine needs to be stopped to calibrate the roller position and tighten the fixing accessories. Severely worn rollers need to be replaced promptly.
Third, check if the equipment's feeding speed fluctuates. Uneven feeding will cause an imbalance in the forming force of the tube. Adjusting the octagonal tube roll forming machine's feeding parameters to maintain a uniform feeding speed will solve most forming deviation problems.
(2) Abnormal Noise During Equipment Operation & Chain Jamming
First, stop the machine and check the chain tension of the octagonal pipe roll forming machine. A loose chain will cause tooth skipping and vibration, while an overly tight chain will exacerbate friction and abnormal noise. Adjust the chain tension according to the equipment's standard parameters.
Then, check the chain surface for oil stains, blockages, or dryness due to lack of oil. Clean the impurities and perform standardized lubrication maintenance again.
If abnormal noise persists after these checks, check the chain pins and rollers for wear and deformation, and check for loose or damaged chain links. Replace aged chain parts promptly to prevent the octagonal tube roll forming machine from operating with malfunctions.
(3) Insufficient Power in Hydraulic System and Operational Stalling
First, check if the hydraulic oil level of the octagonal pipe roll forming machine is up to standard. A low oil level will lead to insufficient oil supply and power loss; simply add the same type of hydraulic oil as needed.
Second, check if the hydraulic oil is cloudy, deteriorated, or contains impurities. Deteriorated oil will clog the oil circuit and reduce transmission efficiency; the hydraulic oil must be completely replaced according to the procedures outlined above.
Third, check the hydraulic lines and connections for leaks and blockages. Tighten any leaking connections and clear any blockages to ensure smooth hydraulic flow and stable pressure in the octagonal tube roll forming machine.