12mm Three Rollers Plate Rolling Machine

As a mature manufacturer of plate rolling machines with over a decade of technical expertise, we are now ready to reveal the functional testing process for the emergency braking system of plate rolling machines:

As a critical piece of equipment for metal sheet forming and processing, the safety performance of a roll forming machine directly impacts the personal safety of operators and the service life of the equipment. The emergency braking system is a core component of the machine's safety measures, capable of swiftly halting mechanical movement in the event of abnormal operation or sudden hazardous situations. To ensure the system remains in a reliable state at all times, a standardized testing process must be established and strictly enforced.

1, Preparations before testing

Before testing, confirm that the equipment is powered off and hang a “Do Not Operate” warning sign on the control panel. Inspect all components of the braking system, including the brake, sensors, and control circuits, to ensure there is no visible damage. Clean oil stains and metal debris from the brake disc surface to keep the friction surface clean. Prepare testing tools, including multimeters, stopwatches, dial gauges, and other measuring instruments, and ensure that they are within their calibration validity period.

Operators should be familiar with the electrical schematic diagram of the equipment and the structural diagram of the braking system, and understand the key control points in the testing process. Wear protective equipment, especially insulated gloves and safety glasses. Notify nearby staff of the start time of the test and ensure that there are no unauthorized persons in the test area.

2, Mechanical braking function test  

First, perform a manual braking test. Loosen the brake adjustment bolt, manually operate the brake lever, and inspect the contact between the brake pads and brake discs. Use a feeler gauge to measure the brake clearance, which should be maintained within the range of 0.5–1.0 mm. Adjust the brake spring tension to ensure even distribution of braking force.

Then perform the no-load brake test. Turn on the equipment power supply and run the rolling machine at low speed (5-10 r/min) without a load. Trigger the emergency stop button and use a stopwatch to record the time from triggering to complete stoppage. The normal value should not exceed 0.5 seconds. Repeat the test three times, record the braking time each time, and the deviation should not exceed 10%.

3, Electrical control system testing

Check the electrical circuit of the emergency stop button. When the button is pressed, use a multimeter to measure whether the control circuit is completely disconnected. Test the circuit self-locking function after the button is reset to ensure that the circuit can only be reconnected after manual rotation to reset.

Verify sensor feedback signals. Simulate equipment overspeed conditions and observe whether the control system can correctly receive speed sensor signals and trigger braking. Check the sensitivity of the position sensor. When the rolling machine's moving parts exceed the set range, the system should immediately activate braking.

Test the backup power supply switching function. Disconnect the main power supply and check whether the UPS can switch power supply seamlessly to ensure that the braking system can continue to operate normally for at least 30 seconds in the event of a power failure. Record the switching time and continuous power supply time.

4, Comprehensive testing under load conditions

After completing the no-load test, a load test must be performed. Select test plates of appropriate thickness (recommended to be 60% of the equipment's rated processing thickness) and perform normal rolling operations. Trigger emergency braking while the plates are moving and observe the braking effect. The sliding distance of the plates should not exceed 50 mm, and no obvious deformation should occur.

Test the overload protection function. Gradually increase the load to 120% of the rated value and check whether the system automatically triggers braking when the critical value is reached. Record the load value and response time when the trigger is activated.

5, Post-test inspection and recording

After testing, thoroughly inspect all components of the braking system. Measure the wear on the brake pads; the remaining thickness should not be less than 1/3 of the original thickness. Check the temperature of the brake discs; after three consecutive braking operations, the temperature increase should not exceed 50°C. Confirm that all fasteners are secure and that electrical connections are reliable.

Fill out the test record in detail, including test time, participants, test data, abnormal conditions, etc. Classify the problems found during testing: minor problems must be resolved within 24 hours, and serious problems should immediately stop using the equipment and report it. File and save the test report as a reference for the next test.

6, Regular Testing and Maintenance Recommendations

The testing frequency for emergency braking systems should be determined based on usage intensity. Equipment in continuous operation should be tested weekly, while equipment used intermittently should be tested at least monthly. After major repairs or replacement of critical components, a full set of tests must be conducted again.

During routine maintenance, keep the braking system clean and regularly replenish lubricants. Pay attention to any abnormal noises or vibrations during braking to promptly identify potential issues. Maintain a record of brake pad replacements and prepare spare parts in advance before reaching the end of their service life.

Through standardized testing procedures, it is possible to ensure that the emergency braking system of the rolling machine is always in optimal working condition. This not only guarantees the safety of the equipment, but also ensures the safety of the operators. During testing, it is essential to strictly adhere to operating procedures and eliminate any form of simplified operation or complacency. Only by institutionalizing and normalizing testing can the safety protection system truly fulfill its function.

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