Prca350A1 Fully Automatic Recropper for Brick

• After-sales Service: Lifetime Free Technical Consulting Service
• Warranty: 1 Year
• Market Share: 100%
• Processing Time: Fully Automatic
• Applicable to: Brick or Squared Bar
• Color: Black
• Model NO.: PRCA350A1
• Transport Package: LCL
• Specification: (L) 4400× (W) 2020× (L) 2760mm
• Trademark: Skywiretech
• Origin: China
• HS Code: 8486103000
• Production Capacity: 1000/Year

Product Description

1. Equipment usage:
PRCA350A1 single crystal square rod reverse cutting machine is a device capable of cutting both end faces of square rods. At the same time, it is equipped with a fully automatic computer control system and uses an intuitive control interface to realize automatic control of crystal ingot length, automatic cutting, automatic knife retraction, post-cut cleaning and drying, etc., and can achieve high-precision single crystal cutting.
2. Performance characteristics:
1) Equipped with a digital display operating platform, servo motor controls the feed speed, and PLC program control to achieve fully automatic cutting.
2) According to the set length, the bar material can be automatically fixed to length, automatically cut, automatically separated, and automatically withdrawn.
3) The main pulley is driven by a servo motor, the linear speed is adjustable, and it has small vibration, low noise and low energy consumption.
4) Through weight loading, constant force feeding is achieved to meet different needs.
5) The cutting surface is flat and circular cutting, without the need for reciprocating pay-off and take-up. Therefore, there will be no wavy lines on the cutting surface and the surface is smooth.
6) Simple line change, loop line equipment, line change is like changing a V-belt, put it on and use it, and it only takes 2 minutes for a skilled operator. There is no need to change the line after a break like traditional drum wire equipment, which takes nearly an hour.
7) The failure rate is low, the loop equipment has a simple structure, the failure rate is low, and the maintenance cost is low.
8) The equipment has a device for adjusting the inclination of the left and right faces, and a rolling friction device is allowed on the bottom surface.
3. Equipment diagram:



II .Main technical parameters and energy consumption of equipment

No.

Item

Value

1

Equipment processing capacity

1.1

Brick spec(mm)

Brick side length:160- 230

1.2

Brick length range (mm)  

120-900

1.3

Cropped segment length (mm)(mm)

≥30  (Brick)

2

Equipment processing capacity 2

2.1

End surface flatness (mm)

0.2

2.2

Verticality(mm)

0.5

2.3

Segment length error (mm)

± 1

2.4

Chips (mm)

0.5

3

Equipment efficiency and productivity

3.1

Pure cutting time (min/knife)

Brick side length:166:    5.5/Brick
Brick side length:182:      7/Brick
Brick side length210:      8.5/Brick

3.2

Auxiliary time (min/knife)

3

3.3

Total machining efficiency (average processing efficiency + auxiliary time) (min/knife)

 

Brick side length:166:	8.5/Brick
Brick side length:182:	10/Brick
Brick side length210:	11.5/Brick

3.4

Total cutting efficiency (average processing efficiency + auxiliary time) (min/knife)

 

Brick side length:166:	132
Brick side length:182:	112
Brick side length210:	97

4

Consumable specifications

4.1

Wire diameter (mm)

0.5/0.42

4.2

Circumference of wire (mm)

2960

4.3

Wire speed (m/s)

0-35

4.4

Wire tension (N)

80-160

4.5

Wire speed (mm/min)

0-750

 

5	Power consumption
5.1	Total power (kw)	7
5.2	Power consumption (kw)	4.2
5.3	power supply	AC 380V 50Hz
5.4	Inlet water pressure (Mpa)	0.3-0.5
5.5	Water consumption (m3/h)	0.6     (10L/min)
5.6	Intake pressure (Mpa)	0.5-0.7
5.7	Air consumption (m3/h)	6    or         100L/min
5.8	Lubricating	Lubrication adopts self-lubricating or grease lubrication, and the grease adopts 0# or 00# extreme pressure lithium grease.
6	Equipment Specifications
6.1	Equipment size (mm)	(L) 4400×(W) 2020×(H)2760 (Excluding operation box rotation size)
6.2	Equipment weight(T)	4.2
6.3	Floor unit area load value (KN/sqm)	4.8
Note 1: It means that the total length of the bar when cutting the current cut shall not be less than 120mm. Note 2: The bar is required to be brick after square root; the bar is not twisted or bent.

6. Equipment technical information
1. Equipment specifications
2. Equipment instruction manual
3. Equipment maintenance manual
4. Equipment outline drawing
5. Electrical schematic diagram
6. Equipment pneumatic schematic diagram

7. Main technical requirements of equipment
1. Complete machine
1) The equipment can realize the functions of automatically pushing the Brick according to the given cutting length, automatically determining the cutting length, and automatically withdrawing the thread after cutting. According to the set length, the bar material can be automatically fixed to length, automatically cut, automatically separated, and automatically unwinded, etc.
(1) Short rods whose length after cutting is less than 100mm cannot be pressed automatically and require manual assistance.
(2) The removed short rods whose length is less than 30mm require manual assistance to automatically withdraw the thread.

2) During the operation of the equipment, it has the function of automatic monitoring of the minimum detection values of water flow and air pressure, and has the function of automatic alarm and shutdown when the cutting process requirements are not met.
3) The overall strength of the equipment is firm and reliable, corrosion-resistant, rust-proof, easy to disassemble and install, and easy to maintain. The movement cylinder is not easy to deform, jam, and has good protection. The electrical detection components in the water-related area meet the waterproof and dustproof level IP67, and are not cutting. The area components are dust-proof grade IP67/IP51 according to the usage environment. The overall equipment must be strong, solid, reliable, corrosion-resistant, rust-proof, easy to disassemble and install, and easy to maintain. Protective measures for key moving parts such as guide rail sliders, screw rods, and bearings are in place, making disassembly, installation, maintenance, and maintenance easy.
4) Equipment failure rate ≤ 1% (failure rate = failure time / total equipment operating time), monthly failure time ≤ 6.5h (except for human factors, auxiliary materials, silicon rods, etc.), noise ≤ 80dB (A) (no abnormal noise ). Important components: The life of the motor guide rail slider screw rod is >1 year, the life of the electrical components is >1 year, the life of the protective cover is >6 months, the electrical cabinet shell is sealed and ensures normal operation at room temperature, the servo cable is >1 year, the servo The controller is >1 year, the bearing service life is 3000h, and the cylinder life is half a year. Normal damage during the warranty period will be replaced free of charge. If standard mechanical accessories and electrical components are damaged, they can be purchased in the market.
5) The device is open to Modbus tcp or OPC UA protocol and can be connected to automation equipment according to the protocol. The equipment control system adopts first-class (PLC, driver) brand specifications, with real-time alarm function (alarm records are saved for >3 months), auxiliary material usage time, and maintenance cycle reminder functions; the operation interface must meet the statistics of bearing, steel wire, and guide wheel usage Life statistics, related processing records, statistical data, etc. can be exported.
6) During the warranty period, there is a safety stock nearby to ensure the equipment can be opened.
7) Provide equipment backup program, free upgrade, and equipped with maintenance manual.
8) The equipment has the ability to independently display output comparison information, personnel operation information, line change information records, auxiliary material service life timeout alarms, failure times/failure times and other related information.
9) It has the ability to automatically determine equipment faults and the location of fault points, and automatically triggers alarms when abnormality occurs; it has the ability to prompt maintenance and standardize inspections. The machine will stop immediately when detecting and alarming at key parts, and will turn on after returning to normal values.
10) The equipment protection mechanism has a safety interlocking function and the human-machine interface has a level 3 password protection function.
2. Upper bracket
1) The height of the loading workbench is convenient for manual loading and unloading. The loading and unloading height is 850±10mm and can be connected to automation.
3. Gear train
1) The guide screw of the gear train lifting and traversing system is strong, reliable, corrosion-resistant, and rust-proof. It is easy to disassemble and install, easy to maintain, and has a service life of >1 year.
2) The service life of the bearing is 3000h, (refer to the system record for the effective running time of the bearing). 3) The workbench and the tightening mechanism are strong, reliable, corrosion-resistant, and rust-proof, and are easy to disassemble and install, and easy to maintain.
4. Blow-drying mechanism
After cutting, the equipment automatically cleans and blows away 80% of the water stains on the upper surface and left and right sides of the Brick (as shown in the picture below), but it cannot blow away the circulating fluid residue attached to the surface.



5. Water supply and drainage
1) The equipment drain outlet has a filter device to prevent debris or debris from falling into the equipment.
2) The water supply port has flow detection and a filter.
6. Electrical
1) The moving part cables use flexible cables, and more than 4 cores are reserved for multi-core control cables.
2) The electrical cabinet is sealed and ensures that the working temperature is <35°C, the service life of the air conditioner is >1 year, and the air conditioner drain pipe layout is reasonable and easy to clean.
3) The service life of electrical components (three-proof treatment) is >1 year, and the service life of servo cables is >1 year.
4) The electrical detection components in the water-related area meet the waterproof and dustproof grade IP67, and the components in the non-cutting area meet the dustproof grade IP67/IP51 according to the use environment.
5) The selection of electrical components must be able to adapt to the requirements of high altitudes above 2,400 meters (insulation performance, arc extinguishing performance of switching electrical devices, etc.). Remarks: Optional items.
7. Lubrication
1) The lubrication system automatically fills oil, the frequency of oil filling can be set, and it has a low oil level alarm and shutdown function.
2) The pipeline layout of the lubrication system is reasonable to ensure that each moving mechanism is lubricated in place.
3) The oil pump operates without failure and the oil pump life is >1 year.


8. After-sales service
1. Preparation work: The purchaser should make on-site preparations in advance according to the requirements of the supplier's "Equipment Specification", designate a dedicated person for docking during the installation of the equipment until delivery, coordinate the training personnel to participate in the entire training period, and actively provide corresponding Assist so that related work can be completed smoothly as planned.
2. Signing for items: The buyer should unload the equipment in a standardized manner and place it properly according to relevant requirements and operating specifications after receiving the equipment. After the supplier's after-sales technicians arrive, they will unpack the equipment together according to the packing list and install it after confirming that it is correct. Sign and confirm on the packing list.
3. Installation: The purchaser should complete the installation work of the equipment according to relevant requirements and operating specifications; so that the supplier's technical personnel can complete the installation work such as horizontal adjustment of the equipment and pipeline connection.
4. Debugging: The supplier's technical personnel will complete the relevant debugging work of the equipment, and the items required for debugging (such as crystal ingots) will be provided by the buyer in a timely manner.
5. Training: The supplier provides corresponding on-site training to the relevant personnel of the demand side. The training content includes equipment principles, daily operations, cleaning, maintenance and common problem handling. The training is conducted during the day shift and lasts no less than 8 hours.
6. Delivery and acceptance: After completing the above work, representatives of both the supply and demand parties will confirm according to the content of "3. Equipment Acceptance Standards". After completion, they will sign (seal) on the delivery form and acceptance form to confirm that if there is any failure to meet the standards, Items can be noted on the document.
7. Warranty: The free warranty period for the equipment is one year (except for wearing parts, use of non-original spare parts and other product problems caused by customer factors), starting from the date of delivery of the equipment. During the warranty period, the supplier will provide a 24-hour telephone number Wait for remote technical support. If remote technical support cannot solve the problem, the supplier should arrange for technicians to arrive on site to handle it in the shortest possible time.
8. Personnel arrangement: The supplier should arrange technical personnel who are familiar with the principle and structure of the equipment and have corresponding after-sales experience to provide after-sales service.
9. Expenses: During the warranty period, the cost of after-sales technical personnel (travel, food and accommodation, etc.) during equipment installation, commissioning, and training shall be borne by the supplier. The cost of spare parts and after-sales technical personnel within the warranty scope shall be borne by the supplier. The party will charge based on the actual after-sales service fees required after negotiation between the supply and demand parties.

9. Safety requirements:
1. Equipment debugging - During delivery, the user should ensure that the operators using the equipment are present and receive training to ensure that the operators are familiar with the equipment operating procedures.
2. To ensure personal safety, during the operation of the equipment, it is strictly prohibited to open the doors and windows of the equipment and perform any operations on the moving parts of the equipment. The supplier is not responsible for compensation for losses caused by the customer's failure to operate in accordance with regulations.
3. Training requirements:
(1) After the on-site installation and debugging of the equipment is completed and the operating conditions are reached, the user shall cooperate with the supplier to organize theoretical and practical training within 7 working days.
(2)The user should ensure that each equipment operation and maintenance personnel receive no less than a total of 20 hours of training before they can start operating.

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