ZQJ-160(160A)

Fully Automatic Stone Cutting Machine

XIAMEN YINHUA MACHINERY FACTORY

ADD.：HUANCHENG EAST ROAD, TONG’AN ,XIAMEN, CHINA

TEL/FAX：0086－592－7135311

Table of Contents

1 / Model, name and usage------
2 / Main technical data ------
3 / Structure andworking principle------
4 / Equipment installation ------
5 / Operation ------
6 / Usage------
7 / Maintenance ------
8 / Wearing parts list ------
9 / Electrical apparatus diagram------(attached drawing)
10 / Foundation diagram------(attached drawing )

A 、Model, Name and Usage

1、Model and name：

ZQJ-160(160A)

Fully Automatic Stone Cutting Machine

2、Usage：

ZQJ-160(160A)Fully Automatic Stone Cutting Machine is one of the series of stone processing machinery products designed and manufactured by our factory. It integrates the advantages of many kinds of stone cutting machines. It adopts a single-column support and single-arm overhang structure. The whole machine has a novel design, above all, the headstock adopts a pair of bevel gears to carry out two-step speed variation , making the running more stable. The machine realizes the overall process automatic cutting according to the preset cutting depth and slicing thickness etc. The process surface is smooth. It features low energy consumption, high productivity, easy operation and high-quality processed slabs, convenient installation and maintenance. It is widely used in cutting granite and marble slabs. It is really ideal for granite and marble processing factories.

B、Main Technical Data

Technical Parameter / ZQJ-160 / ZQJ-160A
Saw blade diameter / mm / Φ1600 / Φ1800 / Φ1600 / Φ940
Saw blade no. / pcs / 1 / 1 / 1
Max. up-down stroke / mm / 900
Max worktable stroke / mm / 3500
Worktable table-board dimensions / mm / 1680×988
Max. stone material cutting specs. / L×W / mm / 3000×1200
H / mm / 650 / 750 / 650
Worktable feeding speed / m/min / ≈4
Saw blade up-down speed / mm/s / ≈4. 8
Slicing traveling speed / mm/s / 2.3
Main motor model and power / kw / Y200L1-6 18.5 / Y200L2-6 22
Up-down motor model and power / kw / Y90L-6 1.1
Trolley motor model and power / kw / YU802-6 0.55
Up-down motor model and power / Kw / Y112M-6 2.2
Water consumption / L/min / 80～100
Outline dimensions L×W×H / Mm / 6000×2900×3300

C、Structure and Working Principle

ZQJ-160(160A) Fully Automatic Stone Cutting Machine

This machine is composed of a column assembly, cutting assembly, worktable assembly and electric cabinet.

The principal axis is rotated by the main motor after the 2-step speed variation through the V-belt and a pair of bevel gears in the headstock. It drives the saw blade to realize the cutting.

After the deceleration and transmission to lead screw through V-belt and speed reducer,the up-down motor drives the up-down nuts to move up and down, thereby driving the cutting assembly to move up and down.

Slicing feeding movements: When finishing cutting a slice, the saw blade elevates automatically to the cutter feeding starting position, the starting motor starts up automatically and stops automatically after driving the cutting assembly to move for a slice width through speed reducer sprocket wheel, leadscrew and nuts, the cutting assembly begins to cut the next slice, like this, until finishing cutting the whole stone material and stopping the machine to change the material.

All of this machine’s mechanical movements are controlled centrally by electric cabinet. The working programs can adjust the electric control parameters according to different stone material processing requirements to obtain optimal processing technical scheme. Once the control program is set up, the overall processing process will progress automatically, enhancing the working efficiency greatly.

D、Equipment Installation

  1. Installation precautions:

1)User builds the foundation in advance according to the foundation drawing for installation.

2)The installation of the column, guide rail, worktable, and electric cabinet should be finished under the direction of professionals.

3)The electric cabinet should be installed in a place without water where it is easy to operate. And it should be earthed firmly.

  1. Installation precision requirements:

1)The gradienter measurement value for the sliding plate guide rail surface =0.04:1000.

2)Principal axis axial drunkenness <=0.02, radial drunkenness <=0.02(dial gauge measurement)

3)The full-length straight-edge/gradienter measurement value for the trolley guide rails=0.04/1000, gauge=880, direction=0.10/1000. scissors difference is not allowed.

E、Operation

First, we should understand the timer in ZQJ-160/160A

There are 5 pcs of timer in ZQJ-160/160A:

(1)2 pcs on the panel of electric cabinet:

One timer control trolley moving: please put the trolley limit switch according to the rotating direction of blade, make sure that the water can not arrive at the switch. As for the trolley moving, one direction is controlled by limit switch, another side is controlled by timer, the speed of trolley moving is about 4.2m/min, please calculate the cutting time according to the length of your stone, then set up the data on timer

Another timer control the cutter lowering quantity:

The reference value: cutter lowering quantity/sec.:4.55 mm

cutter lowering quantity/2 secs.:9.1 mm

Note: In China, our customer usually set up 3-4 seconds, please set this data according to the hardness of your stone, if the data is too larger, high efficiency,but it is very bad for the blade and segment.

(2)3pcs in the electric cabinet:

Timer KT 4 : control the slicing. Set the data according to the thickness of slab you want to cut

Timer KT 3 : blade upwards delay. The meaning is: for example, if you set the blade cut 3cm each time, when the blade is going to reach the bottom of your stone, perhaps it had only a 1cm or 2cm or 1.5cm left. So if there is no this timer, the when the cutter reach the down limit switch, the blade must go up, there are some stone do not be cut.

This timer is control: when the cutter reach the down limit switch, it need not go up, it continue cutting ,and when it finish the last cutting, the blade should go up. So the level of the each slab’s bottom are all according to the level of down switch, are the same.

Please note: the data on this timer is larger than the timer which control the cutter lowering quantity, but smaller than the time that blade cut from one side of stone to another side.

Timer KT 1: controlmotor finishing the Y-Δ process. It is protective measure for another electric parts.

Second, when the machine arrive at your factory, you can see there is a set of portable buttons, please connect the wire to electric cabinet. This portable buttons realize the manual operation

1. Manual adjustments:

(1)First check whether all the electric wiring is correct. Only after confirmation, switch the automatic air switch handle to the “ON” position.

(2)Check the upper/lower limit switches positions. User should check the upper/lower limit switches positions according to the stone material height, making the up-down touching blocks touch the limit switches in the up-down motion, to control the up-down movements.

(3)Check the left/right limit switches positions. User should check the left/right limit switches positions according to the stone material length, making the left/right touching blocks touch the limit switches in the left/right motion, then press the right travel or left travel ,to adjust the time quantum ,so realize the left/right movements.

NOTE: please put the trolley limit switch according to the rotating direction of blade, make sure that the water can not arrive at the switch. As for the trolley moving, one direction is controlled by limit switch, another side is controlled by timer

(4)Adjust the cutter lowering quantity. User should adjust the time relay pointer to the needed position (time ) manually according to the slab hardness.

The reference value: cutter lowering quantity/sec.:4.55 mm

cutter lowering quantity/2 secs.:9.1 mm

2.Auto adjustments:

First finish the manual adjustment procedures (above), then press the portable buttons, let the trolley arrive at the limit switch, start up the main motor. After the main motor finishes the Y-Δ process, press the “auto” button, the trolley will be running to and fro automatically.

That’s all, the machine will cut automatically.

NOTE: please see the panel of electric cabinet, press “auto” button, the portable buttons do not work, the machine will work on AUTO condition;

Press “auto stop” button, the portable buttons work.

If the voltage is not stable, the slicing will be not precise, the thickness of each slab perhaps will be not the same. You need adjust it by portable buttons sometimes.

When you start to cut the stone formally, please control the machine by pressing portable buttons ,familiar to the machine firstly

F. Usage

(A) Before machine startup:

  1. Check whether all the electric wiring is correct, whether all the programs are normal, whether there is anything out of control.
  2. Check whether any limit switches is malfunctioning, whether the touching block can touch the limit switch.
  3. Hoist the stone raw material into the central position of the trolley, adjust and cushion it, to ensure the firmness.
  4. The saw blade’s cross-sectional and radial drunkenness must not greater than 0.5mm.
  5. When starting up the machine manually, check ,according to the raw material length and height, whether the set-up left/right/upper/lower strokes are within a reliable range.(100~200mm must be reserved for the raw material bottom.)
  6. Check whether any of the cutter wheel and fixing screws is loose.
  7. Check whether the sliding plate upper/lower limit switches can be self-controlled.
  8. Select reasonably the cutter feeding speed and cutter feeding amount according to the material hardness.
  9. Check the circular saw blade height . The distance between the lowest edge and the raw material highest point should be 10~20 mm.
  10. According to the requirements, check whether all the slab cutting data are all set up .

(B) Machine startup:

  1. Observe whether the circular saw blade rotation is abnormal. If there is any abnormity, stop the machine immediately ,check it and eliminate it.
  2. Only after the circular saw blade is running stably , it can cut the stone.
    Note: it is strictly prohibited to start up the machine when the saw blade is touching the stone material.
  3. During cutting , there must be adequate cooling water. it is strictly prohibited to cut without any water.
  4. It is strictly prohibited to move stone during the cutting, otherwise the slab will be out of tolerance, or there will be machine trouble.
  5. If in cutting, cutter blockade occurs, the reasons are: (1)belt slippage ,(2)exceeding cutter feeding depth,(3)exceeding cutter feeding speed. It must be dealt with correctly.
  6. Left /right movement length=raw material length+2X200.
  7. After finishing processing the stone raw material, clip each slab with wooden clips firmly at two points and hoist it away from the trolley.
  8. If any abnormity occurs during the cutting, press the “emergency stop” button, analyze the reason. Get on with the processing only after eliminating the abnormity.
  9. The circular saw blade used in the machine should up to the GB11270-1989 standards. The diamond circular saw blade quality affects the cutting efficiency, so present saw blade requirements to the saw blade factories.
G. Maintenance

This machine should be maintained strictly according to the following procedures to give full play to the equipment potential and increase efficiency and economic benefits.

1、Before using this machine, read carefully this operation manual and get familiar with the operation procedures.

2、Oil the headstock, up-down speed reducer, trolley speed reducer with 30# engine oil, and the oil ought to be 2/3 full of the oil tank. After running the machine for the first one month, the used oil should all be replaced. Check often whether there is enough lubricating oil in the oil tank.

3、Oil the sliding plate guiding surface ,up-down lead screw and slicing lead screw. During usage, keep them clean, and add oil once every 8 hours.

4、Replace the up-down nuts, slicing nuts ,etc. (major wearing parts) every half a year.

5、Before using the machine, let the machine run idle for several times, and check if each moving part is exact and reliable. Only after that, the machine can be used normally.

6、Check whether any screw junction is loose, whether the V-belt and chain degree of tightness is moderate , whether the motor is earthed firmly.

7、The saw blade cross-sectional drunkenness must not be greater than 0.5 mm.

8、During cutting , check if the granite raw material is fixed on the trolley stably.

9、After working for each shift, clean out the dust of granite and marble on the worktable, and clean it with water.Oil all the moving parts.

H、Wearing Parts List

Serial no. / Code / Name / Specs. / Installation position / No.
1 / ZQJ -160-01-24 / Up-down nuts / Middle tool carriage / 1
2 / ZQJ-160-01-25 / Slicing nuts / Middle tool carriage / 1
3 / WCJ-80-1/30 / Up-down speed reducer / Column top / 1
4 / XWD2-43-0.55 / Slicing speed reducer / Horizontal tool carriage tail / 1
5 / JZQ-200-1/30 / Trolley speed reducer / Trolley / 1
6 / thrust bearing / 51408 / Lower
bearing carrier / 1
7 / tapered roller bearing / 30206 / Horizontal tool carriage / 2
8 / radial ball bearing / 6311 / Trolley / 8
9 / HG4－692－67 / Framework rubber oil seal / PD95×120×12 / spindle seat / 16
10 / HG4－692－67 / Framework rubber oil seal / PD75×95×12 / Transmission bearing carrier / 8
11 / HG4－692－67 / Framework rubber oil seal / PD60×80×12 / Transmission bearing carrier / 8
12 / V-belt / B - 900 / Column top / 2
13 / V-belt / B –1727 / Main motor / 7
14 / V-belt / B –1143 / Trolley / 3
15 / ZQJ -160-03-16 / Roller / Trolley / 4
16 / JLXK1-411TH / Limit switch / Trolley / 2
17 / JLXK1-111TH / Limit switch / Column / 3
18 / CJX4-189 / AC contactor / Electric cabinet / 4

Note: The product’s parameters are subject to modifications without prior notice.

1