What should be paid attention to in the installation and debugging of servo pump water jet cutting machine?

Matters needing attention in installation and debugging of servo pump water jet cutting machine

With the advantages of high precision and high pressure, the servo pump water jet cutting machine is widely used in processing hard and brittle materials such as metal, stone and glass. Its installation and debugging should focus on "safety protection, precision guarantee and system coordination" to avoid high pressure risk and precision deviation. The specific precautions are as follows:

First, preparation before installation: lay a solid foundation for safety and accuracy.

1. Adaptation of site and environment

Bearing capacity and space: The overall weight of the equipment usually exceeds 1 ton (including water tank and high-pressure system), and it needs to be installed on concrete hardened ground (strength ≥C30, flatness error ≤2mm/m), and the ground bearing capacity ≥500kg/㎡ to prevent long-term operation settlement; 1.5-2m operation space should be reserved around the equipment, especially 2m on the high-pressure pump side (to facilitate the maintenance of high-pressure components), and at the same time, it should be far away from vibration sources (such as other heavy machine tools) to avoid resonance affecting the cutting accuracy.

Water, electricity and gas source: the power source needs to match the rated parameters of the equipment (usually 380V three-phase and four-wire, and the current is calculated according to the power of the servo pump, for example, the 75kW servo pump needs to be equipped with more than 120A open circuit), and it is wired separately and equipped with a leakage protector (rated leakage current ≤ 30 mA); The water source should be clean (impurity content ≤5ppm to avoid blocking the high-pressure nozzle), the water pressure should be stable at 0.3-0.5MPa, and pre-filter and water softener should be installed (to prevent scale formation); If the equipment contains pneumatic clamping mechanism, the pressure of air source should be 0.6-0.8MPa, and the gas pipe should be resistant to high pressure and an oil-water separator should be installed.

2. Equipment and accessories verification

Check the core components according to the packing list: servo pump (including motor and piston pump), high-pressure pipeline (made of stainless steel or high-strength alloy, without cracks and deformation), cutting head (including nozzle and jewel seat), numerical control system and workbench (including guide rail and slide block), and focus on checking whether the high-pressure components (such as high-pressure seals and check valves) are in good condition, and whether the nozzle aperture matches the cutting requirements (such as 0.

Prepare special tools in advance: high-pressure torque wrench (used to tighten high-pressure pipeline bolts to avoid sealing failure), level gauge (accuracy 0.02mm/m), pressure gauge (measuring range ≥400MPa, detecting high-pressure system pressure) and micrometer (calibrating cutting accuracy) to avoid damage to high-pressure components caused by using common tools.

Second, the installation process: strictly control the high-voltage safety and accuracy benchmark.

1. Equipment leveling and fixing

Use a level to detect the longitudinal (cutting direction) and lateral levelness of the equipment base, and adjust it by adjustable anchor bolts to ensure that the error is ≤0.05mm/m (the servo pump and the workbench need to be leveled separately to avoid the vibration of the high-pressure pump from being transmitted to the workbench); After leveling, use expansion bolts (specification ≥M16) to fix the equipment, and the tightening torque of the bolts shall meet the requirements of the manual (usually 80-120 nm) to prevent the equipment from shifting during high-pressure operation.

2. Installation of high-voltage system: put an end to leakage risk.

Pipeline connection: High-pressure pipelines (working pressure is usually 300-400MPa) should be arranged according to the principle of "short, straight and few bends" to avoid acute bends (minimum bending radius ≥ 5 times of pipeline diameter); A special high-pressure gasket (such as copper pad or PTFE pad) should be installed at the flange connection, and the bolts should be tightened with a high-pressure torque wrench in the manner of "diagonally fastening in stages" to prevent high-pressure water from leaking (leakage may lead to pipeline bursting or personal burns).

The servo pump is connected with the water tank: the water tank should be higher than the water inlet of the servo pump (to avoid negative pressure water absorption), and the water inlet pipeline should be equipped with a filter screen (aperture ≤100 mesh) to prevent impurities from entering the pump body; The water tank needs to be filled with special water jet cutting fluid (or pure water, which is forbidden to be directly used with tap water), and the liquid level should be higher than the minimum water level line to avoid the servo pump idling damage.

3. Installation of cutting system and numerical control system

The cutting head shall be installed perpendicular to the workbench (calibrated with a square, and the verticality error shall be ≤0.02mm/100mm), and the nozzle center shall be aligned with the workbench positioning benchmark; The guide rail and slide block shall be clean and free of impurities, and special guide rail grease shall be applied (to avoid precision reduction caused by dry friction), and the cutting head shall be manually pushed to move to ensure no jamming and abnormal noise.

The wiring of CNC system needs to distinguish between strong current (servo pump, motor) and weak current (sensor, control signal), and the wires should be protected by metal pipes to avoid high-voltage interference; The grounding resistance of the system is ≤4Ω (to prevent the failure caused by static accumulation). After wiring, check the drawings to ensure that the signals of the servo motor, encoder and limit switch are connected correctly.

Third, the debugging stage: step by step to verify the safety and accuracy.

1. No-load debugging: troubleshooting system hidden dangers.

Low pressure test: close the nozzle, adjust the servo pump pressure to 50MPa (low pressure), run for 30 minutes, and check: ① There is no leakage in the high pressure pipeline (the flange and joint are coated with soapy water without bubbles); ② The servo motor runs smoothly, and the current has no abnormal fluctuation (≤ 60% of the rated current); (3) the numerical control system has no alarm, and the equipment can stop immediately when the limit switch is triggered.

No-load operation: open the nozzle (no abrasive is installed temporarily), adjust the servo pump pressure to 100MPa, and control the cutting head to move along the X and Y axes. Check: ① the deviation between the moving speed and the set value is ≤ 2%; (2) the guide rail parallelism error is less than or equal to ≤0.03mm/1000mm；; (3) After the emergency stop button is triggered, the servo pump needs to release pressure within 1 second, and the cutting head stops immediately.

2. Load debugging: verify the cutting accuracy and efficiency.

Abrasive adaptation: according to the cutting materials (such as garnet abrasive for metal and quartz sand for stone), adjust the abrasive supply (usually 0.5-2kg/h) to ensure that the abrasive is evenly mixed with high-pressure water (observe whether the "water jet beam" sprayed by the nozzle is in a continuous white column without interruption).

Parameter optimization: set the cutting parameters according to the material type (for example, cutting 10mm thick stainless steel: pressure 380MPa, speed 80-100mm/min, abrasive amount 1.2kg/h), first try to cut the standard sample (for example, 100mm×100mm square), and check: ① the verticality error of the cutting surface is ≤ 0.5; ② The dimensional accuracy is ±0.05mm；; ③ No edge collapse and burr (if any, the pressure, speed or nozzle height should be adjusted).

High voltage test: gradually adjust the pressure of the servo pump to the rated value (such as 400MPa), and cut continuously for 1 hour. Monitoring: ① The high-pressure seal is not overheated (temperature ≤ 60℃); (2) servo pump pressure stability, fluctuation ≤±5MPa；; ③ There is no obvious change in cutting accuracy (the sample size error still meets the requirements).

3. Safety debugging: Strengthen protective measures

Check the safety protection device: ① A metal protective sleeve should be installed on the outside of the high-voltage pipeline (to prevent the pipeline from bursting and injuring people); (2) The cutting area needs to be equipped with a transparent protective plate (to prevent abrasive splashing); ③ The operation panel shall be marked with "High Voltage Danger" warning, and only authorized personnel can modify the parameters.

Simulated fault test: artificially trigger "high pressure leakage alarm" and "abrasive material shortage alarm", check whether the equipment can automatically relieve pressure and stop, and give an audible and visual alarm to ensure the correct fault handling logic.

Iv. acceptance and maintenance: defining standards and post-guarantee

1. Acceptance criteria

Compared with the equipment manual and industry standards (such as the Technical Conditions of Ultra-high Pressure Water Jet Cutting Machine JB/T 11524), the acceptance: ① the cutting accuracy and speed meet the standards; ② The high-pressure system has no leakage and stable operation; ③ Safety protection meets the requirements; (4) CNC system function is normal.

Keep debugging records: including pressure, speed and accuracy test data and fault handling records, and form an acceptance report as the basis for later maintenance.

2. Maintenance tips

After debugging, it is necessary to apply antirust oil to the high-pressure components (seals and check valves) and clean up the abrasive residue on the workbench; Inform the operator: ① check the abrasive quantity and water level before starting the machine every day; ② Clean the filter screen of high-pressure pipeline every week; ③ Check the wear of high-pressure seals every month to avoid leakage caused by extended use.

Through the above steps, it can be ensured that the servo pump water-jet cutting machine is "safe without hidden dangers, with standard accuracy and stable operation" after installation and debugging, which provides guarantee for subsequent efficient cutting and avoids equipment damage or safety accidents caused by high pressure risk or precision deviation.