New type Equpment for manufacturer of Insulator Ball Pin for Glass and porcelain suspension insulator
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New type Equpment for manufacturer of Insulator Ball Pin for Glass and porcelain suspension insulator

12.03.2025

New type Equpment for manufacturer of Insulator Ball Pin for Glass and porcelain suspension insulator

We manufacture process lines for the production of high-voltage insulator rods - flat cross-wedge rolling method new type high metall and time safety technology. The article presents possible options for automation of equipment execution, as well as general technical requirements and conditions for the implementation of this project. The equipment and technologies are already working in 80 implemented projects.

The WRL6012 cross-wedge rolling line is designed to work with replaceable sets of flat rolling tools (upper movable and lower fixed). The movable tool drive is hydraulic. The rolling machine operates using one hydraulic station, which controls one hydraulic drive of the working and return stroke of the upper slider with the upper rolling tool, as well as other hydraulic mechanisms of the line (precise adjustment of the closed height, which changes the distance between the upper and lower tools).

№	Type
1	Cross-wedge rolling line – WRL6012-01 (manual change die tool set, changeover time 20-30 minutes by line operator). This includes temperature control of the workpieces with a pyrometer before feeding them into the machine, as well as a mechanism for rejecting overheated and underheated workpieces. Without heater.
2	One tool set WRL6012-01 (standard fixing with bolts on the line). Including design and production.
3	Cross-wedge rolling line – WRL6012-02 (automatic hydraulic change die tool set, changeover time 5-10 minutes by (change control from the line operator panel). This includes temperature control of the workpieces with a pyrometer before feeding them into the machine, as well as a mechanism for rejecting overheated and underheated workpieces. Without heater
4	One tool set WRL6012-02 (fixing automatic tool changed system). Including design and production.
	Options
1	Induction heating 250 kW-500kW (maximum automatic) of workpieces and automatic feeding of workpieces from a storage hopper volume 2500 kg. This includes temperature control of the workpieces with a pyrometer before feeding them into the machine, as well as a mechanism for rejecting overheated and underheated workpieces. Heating cycle 9-10 seconds
2	Induction heating 250 kW-500kW (simplified automation) feeding blanks from a storage tray with a capacity of 10-15 blanks. (loading of the workpiece tray by the operator according to consumption). This includes temperature control of the workpieces with a pyrometer before feeding them into the machine, as well as a mechanism for rejecting overheated and underheated workpieces. Heating cycle 9-10 seconds

The final cost of the equipment depends on the delivery package and the agreed list of drawings of the products planned for production.

Production time of the line and one set of rolling tools: 9-10 months
The equipment and control system complies with USA standards or (Europe, Russian or needed)
Offer validity period: 20 days;
Delivery terms: "FCA" Minsk (INCOTERMS-2020) (pickup at the customer's expense);
Commissioning works are not included in the cost of the equipment and are performed under a separate agreement. These lines are tested on the customer's material before shipment and after delivery, as a rule, in addition to connection, they do not require lengthy commissioning works, and with experience in working with forging and pressing equipment, they allow Customers to independently put them into operation.

Accompanying technical documentation (in English)

Operation and maintenance manual; a layout solution is provided for the preparation of the production site by the Customer, indicating the locations and requirements for the communications necessary for the line operation.
General technical drawings (assembly drawings of the main groups);
Electronic and electrical, pneumatic, hydraulic diagrams;
To avoid unauthorized changes to the software, the source code of the line control program is transferred after the end of the equipment warranty. Remote service support for the software is provided during the warranty period.
List of spare parts.

Aesthetic, ergonomic requirements

Frame RAL 5005 blue; moving parts and protective screens: RAL1023 (yellow); Enclosures of cabinets and control panels of the electrical part: RAL7035 (gray) (we do not paint in other colors). It is possible to paint the frame and protective screens (except for cabinets and control panels) in another color (as an option: the color of the frame and painted parts of the equipment - anthracite gray RAL 7016. The color of the moving parts and safety elements - bright orange RAL 2008)
Line control in automatic mode from the setup and central control panels.
Standart ambient temperature oC -10oC +50oC.
Storage temperature oC Max. 70°C (for 24 h)
Relative humidity % 80

Rolling is carried out from individual blanks - the heated blank is fed into the machine from the side by the machine loading mechanism. The machine includes a device for automatic feeding of the heated blank into the machine. The machine rolls and forms the forging using the tool. After rolling, the finished forgings are removed along the tray into the container. The machine can be supplied with an automatic feed unit from the storage bin, including induction heating and temperature control before rolling. In the proposed version, the heating of the blanks occurs on the customer's equipment.

The machine is equipped with a system for maintaining a constant thermostatic rolling mode (tool cooling).

High degree of automation. Provides uninterrupted and stable operation of the line with full control of all parameters (including in combination with an induction heater, control of the heating temperature of the blanks and rejection or feeding into the line, a system for cyclic feeding of blanks from a slide hopper, rolling of forgings and transfer to the next production stage);

Technical data line WRL6012 without induction heater:

Production cycle: 6-7 sec ( Line output capacity: single rolling – more 514 parts/hour;
Line power –100-120kW; (3 phase 480 V 60Hz ). The billet heating unit is not included in the line set
Cooling water consumption 0,2…0,4 МPa, m3 / h - up to 20 (not more ≤25°С)
Compressed air 0,4…0,6 МPa, m3 / h – not less than 25 m³ / hour. Use components «Festo», «Camozzi»
Parameters for adjusting the closed height of the tool, mm: 158…164
Movable die length – 1200 mm;
Die tools forming length – 1200 mm;
Die tools forming width – 500 mm;
Time for tool changing – 10-20 minutes (bolt fixed scheme);
Blank diameter, mm – 10…60 mm;
Blank length, mm – 60…150 mm;
Rolling part diameter, mm –10…60 mm;
Working with heated workpieces heated to temperatures C˚: 900...1200;
Control System PLC-based, HMI panel (Allen Bradley) consists of a mobile control unit and electric cabinet (on request it is possible to use controllers from other manufacturers);
Electric cabinet and control panel cabinet “RITTAL”, engress protection: IP65.
Switching equipment from high quality companies «Telemecanique», «Allen Bradley», «Siemens», «ABB», «Schneider electric»,. Wire – Helukabel ;
Gearmotors – «Siemens», hydraulic components – «Parker»;
Shut height adjustment capability with the remote control during operation;
Management system that is based on a programmable controller, allows the line to work in the adjustment and automatic modes with the withdrawal of all the settings on the operator panel;
High degree of automation. Provides smooth and stable operation of the line, with full control of all parameters;
Weight lines, kg – 11 000

The line WRL4013 includes:

Rolling machine;
Block for feeding blanks into the machine;
Conveyor for removing rolled parts from the machine;
Pneumatic equipment;
Hydraulic equipment (hydraulic station, communications connections);
Control system (control cabinet, control panel, communications connections);
Tool changer;
Operation manual, electrical, pneumatic diagrams, etc.
Induction heater blank (option)
Accumulating bin with automatic feeding of blanks (option)

3D model complete delivery WRL6012 (without heater)

Lines WRL6012 use an efficient automatic cooling system for die rolling tool set

Container load planning – WRL6012 and one tool set without induction heater

Planning Lines WRL6012-01 without heater

Lines WRL6012-01 without heater (include load blank mechanism in rolling machine)

Planning Lines WRL6012-01 with Induction heating 250 kW (simplified automation)

Lines WRL with heating 250kWt or simplified automation

Planning Lines WRL6012 with heating and full automatic loading blank from vibration bin

Lines WRL with heating 250kWt or simplified automation

Line WRL with a die tool set

Rolling machine / hydraulic station / control cabinet

Control cabinet / hydraulic station

Hydraulic component / Conveyor for removing rolled parts

HMI Operator Panels

Easy die element from tool set. Tool production and maintenance does not require sophisticated equipment.

Die (wedge tool) life (Steel element M2):

between repairs – 100 000…150 000 cycles;

total – 1 400 000 – 2 500 000 cycles;

Real foto the process of forming one cycle a part from a heated workpiece (end process view / side process view). The upper part of the tool moves from left to right, forcing the workpiece to rotate along the surface of the stationary lower part of the tool and the movable upper part, coming into contact with a set of wedge elements that give the workpiece the shape of the required part.

The universal rolling line allows you to work with a large number of changed tools.

We are looking forward to mutual beneficial cooperation!

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