High Speed Vacuum Rectangular Seamer IMC-BG100 INTERNATIONAL MACHINE CONCEPTS WELCOMES YOU TO YOUR NEW MACHINE

Transcription

1 High Speed Vacuum Rectangular Seamer IMC-BG100 INTERNATIONAL MACHINE CONCEPTS WELCOMES YOU TO YOUR NEW MACHINE Operation Manual: Date Version 1. Serial Number 1

2 CONTENTS Chapter 1 Machine Description 1.1 Uncrating Instructions 1.2 Installation 1.3 Electrical and Pneumatic connections 1.4 Chapter 2 Technical Parameters and Description 2.1 Chapter 3 Operation Instruction The can conveying system The lid matching system The first operation system The adjustment of the first operation rolls The adjustment of the first operation head The seaming system The Seaming Head The adjustment of the seaming head The height adjustment of the seaming head The adjustment of the can knocking system The adjustment of the can conveying synchronizing chain The adjustment of the can lifter plate Adjustment of pressure on the can lifter plate The Height Adjustment of the can lifter plate The under- drive system Chapter 4 Malfunctions (Faults) and their rectification Chapter 5 Table of possible faults 4.1 Cleaning Instructions 5.1 Maintenance Instructions 5.2 2

3 Chapter 6 List of main Mechanical Parts 6.1 List of main Electrical Parts 6.2 Chapter 7 Electrical Diagrams 7.1 Chapter 9 Spare parts list 9.1 Chuck and Roller drawings 9.2 3

4 Chapter Machine Description The IMC- BG100 is a single- head full- automatic vacuum can seamer with a first operation mechanism in synchronous rotation. The double seam automatic vacuum can sealing machine with functions of vacuum suction, automatic can body distribution and automatic capping and two pairs of sealing rolls, is suitable for the vacuum suction and capping of square tinplate cans filled with meat mix of Luncheon meat type. Due to the integration of pre- seaming and seaming functions, the stability of the filled can in the equipment during the movement is greatly increased. The soup and or meat sauce in the can will not spill, thus ensuring the weight of the can. To guarantee its safe operation, this machine has several following devices: The lid interlocking device When a can enters the lid interlocking device, the device will cover it with a lid. When no can enters it, it will not dispense a lid. The automatic stop device for machine fault When in operation, if some mechanism breaks down or the lid gets stuck in the operation, the clutch located in the driving transmission box will trip off automatically and the travel switch will be triggered and make the rapid stop. Do not start the machine after a fault without clearing out the fault that caused it to stop Safety instructions This machine is designed and manufactured in accordance with the recognized technical specification and safety requirements applicable to the machine of such type. Despite that, improper operation on this machine is still dangerous and may cause harm and damage to the machine and other properties. 4

5 1.1 Un- crating Instructions During un- crating make sure that no physical damage to the outside of the crate has taken place. Carefully break open the exterior panels to reveal the machine and its working parts. The machine will be covered in a plastic protective cover. This is to be removed. Make sure that no parts have been damaged during transport, or fallen off the machine. The machine will arrive with certain parts dis- assembled. These need to be fitted to the machine to resemble the photos above the machine. The machine is fixed to the wooden palette by multiple metal brackets. Remove these brackets and discard or keep for future use. The doors and covers have been taped closed for safety reasons, these taped parts can now be opened. Surface rust can take place due to the excessive sea air during shipping. This will only be surface rust and a dry cloth should be used to remove this rust residue. The entire machine has been shipped with an oil coating on the surface to safeguard the machine from corrosion. This can now be removed with a very light detergent. The non- stainless steel parts should be re- oiled to prevent rusting taking place after cleaning. Do not leave the machine wet. The machine is top- heavy and as such, care should be taken when handling the machine and removing it from its wooden pallet. NOTE: DO NOT HANDLE THE MACHINE ON THE PRODUCT HOPPER. These parts are critically aligned and should they be bent out of position the machine may be damaged. v 1.2 Installation Only a qualified technician should perform the machine installation or a suitably trained person. Note: it is dangerous to work on a moving machine and the machine should be off and isolated before any form of work is performed. Machine should be placed in a well- ventilated room, free from dust and excessively corrosive materials. There should be at least 1,5m space around each side of the machine for convenient operation and maintenance. Prepare the power supply 380V 3 PHASE 50HZ. Three Phase and neutral, and connect to an appropriate earth wire. Pneumatic connections should take place as the designated connection. The air should not be less than 6Bar while the machine is operational. Air should be free of water and contaminants. The machine should be placed on level ground. After installing the machine, check if the machine is level by Level Instrument. If not, please adjust the four legs. 5

6 Check every part of the machine carefully for damage during shipping. Tighten any loose parts, screws and moving parts. All gearboxes should be checked for sufficient oil. Check all electrical connections for loose wires. Make a test of the machines electrical power and confirm the voltage and earth continuity. All safety connections relative to your own country should be adhered to. Before operating the machine, please lubricate: The Filler has a oil reservoir in the upper portion of the machine. Please check to see that no water has ingressesed into this area and that there are no foreign contaminants. 1.4 Electrical and Pneumatic connections This machine requires a three phase connection and earth wire and a pneumatic air connection for a suitable compressed air supply. Electrical Connections Vacuum and Air connection v DISCLAIMER IMC will not be held responsible for incorrect installation and subsequent failure of the machine due to any installation procedure not being followed. 6

7 Chapter Technical Parameters and Description Voltage Power Requirement Dimensions Maximum meat fill volume Weight Maximum Machine Speed Minimum Machine Speed Air Pressure Required Air Volume Required Can Sealing Sizes Can Height Vacuum degree V at 50Hz + N + earth 4Kw mm 800mm (Height) 2.100kg 100 Cans/min 10 Cans/min 0.6 Mpa 10L/Min 100mm diagonal for square cans 30-50mm ~66.661kPA Chapter Mechanical description and adjustments The machine consists of six components, namely the can conveying system, the lid matching system, the first operation system, the seaming operation system, the under- drive system and the control system The can conveying system The can conveying system is composed of the conveying chain, the can separating helix, the conveying bridge and the transmission case (Figure 2). The cans are fed through the conveying chain on the transporter bridge, go through the can separating helix and then enter the can pulling tray in the first operation system one by one separately. Figure 2 The can conveying/in- feed conveyor system 7

8 3.1.2 The lid matching system The lid matching system is composed of the lid falling chute, the lid separator, the lid falling turntable, the can and lid controller, the lid conveying guide rail, the lid receiving guide rail and the lid conveying chain (Figure 3). When the can and the lid reach the turntable in the first operation system, they will be sucked by the vacuum head and enter the first operation mechanism. Figure 3 The lid matching system The first operation system This system clamps the can from the can feed system and the lid from the lid matching system and rotates them. The can and the lid then are chelated with the first operation roller. For the can and the lid are to be vacuumed and seamed by the can sealing mechanism, the can and the lid in the first operation mechanism cannot be chelated too fast to avoid the influence on the vacuum degree in the can. The first operation mechanism consists of four first operation heads, one first operation roller, one rotor, one cam and one turret (Figure 4). Rotating the hand wheel for can height adjustment enable the entire first operation hand piece to move up and down to accommodate can bodies of different height. 8

9 Figure 4 The first operation system Figure 5 The pre- seaming mechanism 9

10 3.1.4 The adjustment of the first operation rolls The level of tightness of the first operation seam is adjusted in accordance with the distance between the first operation head and the groove bottom of the first operation rolls. a. Loosen the two lock screws on the first operation upper swing arm, adjust screws 1 and 2 to make the lower swing arm swing to the closed position; b. Loosen screw 3, swing the inner swing arm to the closed position, then the adjustment of the level of tightness of the first operation seam is realized. After the adjustment in place, all screws should be tightened. The height of the first operation rolls can be adjusted according to the first operation head s clamping on the cans and the lids (Figure 5) The adjustment of the first operation head The height of the first operation head can be decided on the position of the first operation cam. Before the can body enters the positioning turntable and the first operation head catch a lid and send both the lid and the can body to the first operation mechanism, turn the head adjusting sleeve of the first operation cam (Figure 4), make the first operation head move up and down for adjustment, let the lid compressed to the can body (normally the head is compressed down around 1mm), then screw the bolt to immobilize the first operation cam. The four fist operation heads should be adjusted one after another and the space between them should be the same. This can be realized by increasing or decreasing the thicknesses of head spacers. 10

11 3.1.6 The seaming system The seaming system is the can seaming mechanism of the machine, mainly composed of the seaming head mechanism, the can knocking system, the turntable system and the can supporting system (Figure 6). Figure 6 The can seaming system The Seaming Head The can is fed onto the turntable and then turned to the seaming hand- piece for vacuum suction and seaming. The seaming is a sequential seaming operation with the first and second seaming roll pairs, making the lid and the can body joint with five layers of sheet iron. Elastic packing is used in the seams for tightness to achieve the effects of fast hook and hermetical seaming. Among that, the first operation is to make the lid hooked and the can body curled. In accordance with the technological requirements of seaming, the ideal is to make the can body and the lid interlocked into an initial seam of a certain shape and size. The second operation is to hook further the formed good initial joint and exert high degree of pressure to make the seam uniform in density. The first and second seaming rolls complete the seaming process of 11

12 cans of different shapes on the seaming head. The seaming roll on the seaming head of the machine makes the seaming eccentric shaft swing through driving the feed swing arm with the seaming feed cam, thus making the seaming roll on the seaming swing arm approach to perform the seaming process. The movement curve of the seaming rolls advances with the head through the conjugated exploratory. Figure 7 The seaming head The adjustment of the seaming head The seaming rolls are installed on the axle of seaming rolls and fixed on the seaming swing arm. By rotating the adjusting screw of the seaming roll axle, the clearance height between the seaming roll and the head can be adjusted. By adjusting the tilt angle of the feed clamping arm with the puller bolt, the bite during the seaming roll s seaming process can be adjusted to change the thickness of the seam. During the adjustment, the lock screws should be loosened. After the adjustment, the screws must be tightened up again. Head, the main seaming component of the seaming head varies from the diameter of the can to be seamed. Therefore, every can diameter should be outfitted with a set of heads and conjugated exploratory. The seaming capacity of the seaming rolls need to be adjusted. The adjustment is made from the first operation seaming roll, with other three seaming rolls in non- can sealing status. Then the other first operation seaming roll, a second operation seaming roll and the other second operation seaming roll will be adjusted in sequence. Then the adjustment is done. The height of the head relative to that of the seaming roll should also be adjusted properly to guarantee the quality of the seams. The adjustment should be benchmarked against the first operation seaming roll. (the distance between the lower part of the major diameter of the seaming roll and the upper part of the major diameter of the head is 0.05~0.07mm). When the relative height is properly adjusted, tighten the screws. 12

13 3.1.9 The height adjustment of the seaming head Due to the accumulative errors in the machining and the assembly, the height of the seaming head should be adjusted to meet the requirement. The height of the seaming head is determined by the relative location between the head and the tray. According to the design requirements, the distance between the bottom of the tray to the upper end of the head s major diameter is 18mm. The height of the seaming head is adjusted as follow: a. Loosen the lock screws of the hand pieces; b. Rotate the four hand pieces to adjust the swivel nut. In this way, the entire hand piece can move up and down to satisfy the height requirement for the hand piece. Figure 8 The height adjustment of the seaming head The adjustment of the can knocking system The can knocking system is installed on the heading axle and used to knock down the can that has finished the seaming process in order to avoid the can jam due to the sluggishness of the can s leaving the head. The can knocking system should be adjusted to an appropriate height. If it is too high, it cannot knock down the can. If too low, the can may be damaged and made a waste. When adjusting its height, loosen the nuts over the compression spring seat and rotate the heading axle, then the height of the can knocking system can be adjusted. When the height is adjusted in place, fasten the nut. 13

14 Figure 9 The height adjustment of the heading axle The adjustment of the can conveying synchronizing chain It is the can conveying synchronizing chain that transfers the can from the first operation mechanism to the seamer. During the adjustment, a can body and a lid are sent to the first operation mechanism first, then the pre- seamed can will be sent to the synchronizing chain by the can pulling tray. At this moment, the claw on the synchronizing chain will put the can in the fork of the eight- fork turntable. If the can sending is correct, the eight- fork turntable begins rotating when the can is in the prong. But the can sending is incorrect, the tensioner sprocket of the synchronizing chain should be loosened. In this way, the synchronizing chain can move at will to make the claw at the required place. 14

15 The adjustment of the can lifter plate Figure 10 The can lifter device Adjustment of pressure on the can lifter plate The pressure on the can body generated by the can lifter plate increase with the rising can diameter. Thus, the pressure should be adjusted according to the can diameter in the production. During the adjustment, rotate the adjusting screw (M48x1.5) in the collective sleeve of the can lifter device to change the spring pressure. Roughly speaking, the can diameter is increased by every 10mm, the pressure will be increased by 2.5~3kg. But the pressure on the can lifter plate is limited to around 80~100kg The height adjustment of the can lifter plate The height of the can lifter plate should be subject to the tool panel on the engine base. During the adjustment, loosen the lock bolts on the lower part of the collective sleeve of the can lifter device and rotate the eccentric shaft to make the can lifter plate reach the height of the panel. Generally, the can lifter plate can be adjusted 0.5~1mm slightly below the panel. After the adjustment, remember to tighten the lock bolts. 15

16 The under- drive system Figure 11 The under- drive system 16

17 Chapter 4 Malfunctions (Faults) and their rectification Fault Machines will not switch on Machine will not run Rectification Check power supply to machine Check main isolator is in a reset position Check that hand- wheel is not engaged if engaged the machine will not run disengage hand- wheel Machine runs too slow Check emergency stop is not pushed (turned) Increase speed on main panel Machine has mechanicle obstruction, use handwheel to check for mechanicle movement if still obstructed open machine and clear obstruction. 17

18 Chapter 5 Operation steps and Maintenance Instructions 5.1 Operation steps Note: Always clean the machine before operation and discard any foreign materials from the machine Before the machine is powered on and started, be sure that nobody is endangered for that. When the machine table is in operation, it is forbidden to touch any moving part of the machine. You can only touch it when safety is ensured. Do not let the machine run unattended. When it is in operation, pay attention to abnormal sound. If there is an abnormal sound, find the causes and solve the problem. If the malfunction occurring will endanger the operators, the machine table should be shut down. Only after the trouble removal, can the machine be started again. The rules on the safe utilization of electric power must be strictly followed. To prevent the electric leakage, the machine should be reliably grounded. Electrical components and the solenoid valves can never be permeated by the water. Start the motor and bring the entire machine into operation by inching and observe the idling condition to see whether it gets stuck and makes abnormal noise. When putting the vacuum pump in the first operation mechanism, the sound of air suction can be heard. At this moment, a small amount of can bodies and lids can be fed into the mechanism. If they are handled in a coordinated manner, the can bodies and lids can be properly seamed and sent out. In this way, the machine can be put into normal operation. After confirming that machine is properly adjusted and the lubrication is normal, the machine can be operated. When operating the machine, the operator should turn the gear manually first to check whether the parts of the entire machine are normal. When there is no abnormal phenomenon, the machine can be operated in a motorized manner. During the use, the operator should abide by all signs on the machine and pay attention to safety. For parts, especially the vacuum chamber, the vacuum accessories pipe, heads and the seaming rolls, the operator must keep them in good repair, free of any collision or scratch. The shapes and the dimensions of the can bodies and the lids used in the machine should conform to the specifications indicated in Canning Industry Empty Can Standards. The can bodies and the lids should be even, clean and free of repeated folds, rusts or stubborn dirt or related parts such as the heads and the seaming rolls will be damaged. 5.2 Maintenance and Cleaning instructions Note: Do not maintain the machine while in operation 18

19 1- Good lubrication is one of the important conditions to guarantee the rational use and the smooth operation of the machine. For the lubrication of matching parts of the equipment, lubricating devices are equipped in and outside the machine. The lubricating system has four subsystems. The centralization lubrication with machine oil In the hand piece of the seaming in the upper transmission, the transmission of helical gear is lubricated with oil splashing from the oil bath. In the under- drive system, the machine oil is sent to the gear drives and cam mechanisms and bearings through the gear oil pump and the oil- way distributor. The oil cup lubrication with thin oil Used for the lubrication of bearings in the hand piece, inner bearings in the first operation mechanism and gears. The oilcan lubrication with thin oil Used for the lubrication of the lid conveying turntable, the can conveying chain, the headstock guide rail, the eight- fork turntable, etc. The oil nozzle lubrication with lubricating grease The first operation mechanism, bearings, the upper machine base, the can knocking swing arms and the under- drive eight- fork spindle are lubricated with the lubricating grease. During the production process, the oil levels in the upper drive and the under drive oil baths, the turbidity of the lubricating oil should be checked regularly. And the inlet of oil pump should be examined to find out whether the oil filtering is blocked. When a new machine is put into use, the lubricating oil in the oil box must be replaced after 300 hours. The later oil change will be made depending on the turbidity of the lubricating oil and the moisture in it. It s about once per six months. The oil nozzle of the hand piece should be oiled every two hours and other parts are to be oiled one time per shift. Oil types and numbers Thin oil cup and oil bath. The oil pump uses No. 32 machine oil (GB443-84) For the eight- fork turntable, the thin oil oilcan contains No. 32 machine oil. For other parts, No.50 machine oil is used (GB443-84) and the lubricating grease used is ZG- 3 calcium base lubricating grease(gb491-65) Cleaning Procedure The machine should be cleaned frequently. Especially when it is not in operation, all acidic or alkaline liquids contained in dirt and polluted water attached to the machine should be cleared for they may corrode the metal parts. then the finished surfaces of moving parts and the precision parts should be filled and smeared with lubricating oil (grease) and rust- 19

20 preventive oil. Besides, the equipment opening should be made to rotate a while to make the lubricating oil (grease) to permeate the clearance in the running machine. When the machine is not to be used for a long period, apart from the treatment above, rust protection and oil sealing should also be made to the entire machine. After that, cover the machine with a dust guard or a plastic bag. 20

21 Chapter List of main mechanical parts 6.2 List of Main Electrical Parts The electrical installation Supply voltage: three phase current, 50HZ, 380V Motor: Y112M- 4, 4kw The electrical schematics The electrical schematic diagram of this machine, see the figure below. The electric equipment is mainly composed of power switch HK, fuse protector RD, contactor JC, thermal relay RJ, control transformer KB, signal lamps 1XD and 2XD and working lamp BD, start button QA, stop button TA, limit switch XK and electromotor LD. Rotate the power switch to ON location and then push the Start button QA, the coil of contactor JC will be electrified and the normally open contact JC will close up and lock itself. Then motor LD starts running. Push Stop button TA, the coil of contactor JC will be de- energized and the normally open contact will be reset and disconnected. Then the motor stops running. To protect the motor from getting damaged due to the overload, a thermal relay RJ is installed in the circuit for overload protection. Fuse protectors RD are installed in the main circuit and the control circuit for short- circuit protection. Contactor JC is installed in the circuit for no- voltage protection. The machine has the signal device. It adopts a voltage supply of 6.3V. When the machine is in proper operation, the normally open contact JC of the contactor is closed and the signal lamp of 1XD is on (green). When the machine is not started or stops running, the normally close contact of the contactor will close up and the signal lamp of 2XD will be on (red). This machine is provided with the machine tool working lamp for illumination. The safety voltage supply of 36V is adopted and the lamp power is 60W. Care and maintenance of the electric appliance HK is used as the power switch and cannot operate with load. Clear away the dust on the electrical components, examine the contact condition of the contacts and measure the insulating properties of electrical components regularly. Examine the ball bearings of the motor regularly, replace the lubricating grease after the cleaning and replace the bearings without delay if abrasion is spotted. 21

22 Chapter Electrical Diagrams PROJECT DESCRIPTION PROJECT NUMBER DATE Seamer IMC-BG100 - Meatco Electrical Diagram 1 of 2 May 2017 DRAWING DESCRIPTION DESIGNER REVISION Main Circuit Michael Murphy Version 1 PROJECT DESCRIPTION PROJECT NUMBER DATE Seamer IMC-BG100 - Meatco Electrical Diagram 2 of 2 May 2017 DRAWING DESCRIPTION DESIGNER REVISION Interlock Circuit Michael Murphy Version 1 22

23 Chapter Spare parts list Spare parts for Seamer: Recommended Qty. 1. Press Head 5 2. Pre- Seaming Roller 2 3. Seam Roller I (Manufactured in Taiwan) 2 4. Seam Roller II 2 5. Sensor 8 6. In- feed chain finger Chuck and Roller drawings HOPPER MIXER DRIVE MOTOR PROJECT DESCRIPTION PROJECT NUMBER DATE CHUCK AND ROLLERS FOR RECTANGULAR CANS 13 DECEMBER 2016 DRAWING DESCRIPTION MEATCO CANNING SYSTEMS DESIGNER REVISION 23

24 24