Demirci Makina manufacturing of Automatic Wire Fence Weaving Machine,Double Spiral Chain Link Fence Machine, Wire Mesh weaving Machine since 1988

 

INSTALLATION OF Chaine Link fence Machine

This machine requires an operation area of 7m x 5m. Machine can be moved to the operation area by means of a forklift or crane. There is no need to take the machine onto the bridge scale within the operation area. If the legs on the right hand side do not touch the floor, leaving a space then, such space may be filled with wooden or metal elevation chocks. This is intended for the machine to operate free from any vibrations. After having moved the machine into the operation area, firstly take off the sheet plate cover by removing the butterfly nuts. (FIGURE 5). Take out the tools and tool set from the chassis. Remove the transparent nylon stretch film on the control panel (FIGURE 4). Attach the wire loading poles to the chassis with the help of four bolts (FIGURE 2). Prior to inserting the plug (FIGURE 3) into the jack, ensure that main circuit breaker is switched off. Middle tip of the standard plug contained on the machine is neutral. Avoid any electric current contact to this point. Insert the plug into the jack.

 

CONTROLLING THE ROTATIONAL DIRECTION
        
Switch on the main circuit breaker. Move the operation arm (FIGURE 6) to “right” (start”) position for a while then, back to left (stop) position again. During this time, watch the rotational direction of the motor pulley (FIGURE 7). If the rotation is reverse then, change the connection of two phases and check the rotation again. Proper rotation of the main motor means all motors rotate in proper direction. Never interfere with the inside of the panel or cable connections of the motor. When the rotational direction control is completed, switch off the main circuit breaker.
            IMPORTANT NOTE: Rotational direction control is performed when belts are not fastened. Removing and fastening the belts must be performed when the main circuit breaker is switched off.

 

CONTROL PANEL

There is no need for any interference with your AD3 Model machine while it is in automatic operation. However, manual operation is unavoidable every now and then.

Circumstances where manual operation is unavoidable.

1. Depletion of raw material coil (exhaustion of wire)
2. Operator's attempt to replace mould. For instance, intention to switch to 6x6 cm spacing while knitting at 5x5 cm spacing.
3. Operator's attempt to change the fencing width. For instance, intention to knit wire at width of 2 m while knitting at 1,5 m.
4. Automatic stop of the machine due to unexpected irregularity occurred in raw material flow (Indicating lamp gets switched on).
5. Upon an unexpected error, automatic halt of the machine due to the fact that wire knitted gets stuck. (Indicating lamp gets switched on).
6. Start and end of working day.
7. Power cut, etc.

 All interferences above are performed through button, circuit breaker, latches and operation arm contained on the control panel (FIGURE 8). Use of control panel is as follows:

MAIN CIRCUIT BREAKER
It is used for switching on and off the electric power to the machine. There are two positions. At position “0” or when the latch is vertical in other words, the machine is switched off. At position “1” or when the latch is clockwise, the machine is switched on. Boron Oil motor is directly connected to this circuit breaker and when the machine is at position “1”, it should be observed that boron oil flows from the two valves. If not, such flow must be ensured by checking the valves and water in the tank. At the end of a working day and when power cut occurs, the machine is switched off by moving the circuit breaker to position “0”.
CUT-OFF BUTTON
When the machine is in automatic operation or Manual-Automatic latch is horizontal, machine cuts the wire automatically. When the machine is not in automatic operation, cutting is performed by making use of such button. Fencing knitting length is progressed all along. When cut-off button is pressed, shears will be activated and wire will be cut. In case of pressing cut-off button for a short while, button may not be operative. It is appropriate to press this button for an approximately 2 minutes.
ROLL LENGTH SPECIFYING COUNTER
It is a counter with digital display, which is used to specify the length of knitted wire packages, i.e. rolls. It is discussed in detail in the section called “COUNTERS”.
FENCING WIDTH COUNTER
It is a counter with digital display, which is used to specify the height, i.e. width of the fencing. It is discussed in detail in the section called “COUNTERS”.
ROLL LENGTH COUNTER RESET BUTTON
Reset the current status of the roll length counter. It is activated by one short push.     

ROLL LENGTH COUNTER INCREASE BUTTON
Increase the current status of the roll length counter. With each short push, current status is increased one level.

            MANUAL – WITH AUTOMATIC LATCH
            It allows the operator to choose between “Manual” or “Automatic” operation modes. It has two positions. When tailed latch is vertical, the machine is in manual operation. If the latch is turned clockwise, “automatic” operation is selected.
IMPORTANT NOTE: 1- Switching from manual operation to automatic operation must always be performed immediately prior to pressing “manual cut-off button”. In other words, it must be switched to automatic mode before the “wire advances along the knitting length and is cut off”.

                                   2- For a secure operation, the latch must be vertical (for manual use) in respect of any tune-up, repair, maintenance and troubleshooting.

BUTTON FOR CORRECTING ERROR STATUS
            SLOW PROGRESS BUTTON
            This button has two different functions.
            There are stop switch and sensors that control the raw material flow and wire knitting in the machine. When there occurs any error here, machine stops automatically and warning lamp is switched on. When operator performs the necessary interference and rectified the error, he then ensures operation by pressing this button. When this button is pressed, warning lamp is switched off.
            If the button is pressed when there exists no error, the main circuit breaker is switched on and operation arm is at the “left” (stop) position then, the main shaft turns half way and wires advance a length of half pitch. If the button held pressed, wire is knitted at a very slow pace and advances accordingly. Such progress at a very low pace allows that last several revolutions are performed while the wire is knitted along the lay-off arm at manual position.
            ERROR WARNING LAMP
            In case of any problem caused in the flow of wire from the wire coil or wire knitting, machine is halted by means of stop switch or sensor. Operator may understand the existence of such incidence through error warning lamp.
            EMERGENCY STOP BUTTON
            If the machine is intended to be stopped for whatever the reason, it will be sufficient for the operator to press the button for a while.   
            COVER OPENING HANDLE
            It is used for opening the control panel. Cover is opened by operator’s slight pull of the handle. Cover can be closed with a quick flip of a finger. Operator may close the cover by clicking it into its place with a slight push.
            LABEL
            It has no significant meaning in contemplation of use. It is metal plate showing the logo of the manufacturing company.

COUNTERS

There are two counters on the control panel. These counters are exactly identical in terms of all their respective features and they are used for determining the roll length of upper counting roll. Lower one is used for determining the fencing width.
           
            ROLL LENGTH SPECIFYING COUNTER
            Number of roll length spacing is determined according to the mould employed and length of desired roll winding.  For example, if a wire with spacing of 5x5 cm is to be knitted then, 230 box-wires in the roll length of 20 m must be knitted. In such case, number 230 is coded in the desired final status display (FUGURE 9).
            While knitting wire, current status display is incremented 1 at a time after each cutting procedure and when the number reaches 230, machine gives voice warning, indicating that roll length is defined.

Following this, current status display is reset automatically and a new roll is started to be wound. Programming of the desired final status display is performed as follows: if any of the program buttons contained in FIGURE 9 is pressed briefly, a number starts blinking on the desired final status display. After this, each button located right under the 4-digit desired final status display could be used as an increment button for a digit immediately above.  For example, if we want to change the number 130 to 260, we first need to press one of these four buttons briefly and then press 1. Program button briefly three times and 5. Program button briefly once. After the completion of the procedure, blinking of the number of the desired final status display is stopped automatically after a short pause. This shows that the programming is completed.

FENCING WIDTH COUNTER
This counter counts each half round of main shaft as one pace. When the desired fencing width is attained, it ensures that machine starts cutting by stopping the progress of the machine. When the mould or fencing width is changed, it must be re-programmed. For example, if the desired final status display of this counter is programmed as 39 and the fencing width is changed as 1 m while it is operated at 1.5 m fencing width with a spacing of 5x5 cm, the desired final status display must be re-programmed. For this purpose, one of the program buttons is pressed briefly as in the case of roll length specifying counter and it is monitored that number blinking on the desired final status is 39. After this, second program button is pressed 7 times and 4. Program button is pressed 9 times successively and the number blinking on the display is programmed as 26. If time is allowed, this display is fixed and programming is completed.

            EXIT DURATION INDICATING LAMP (FIGURE 9)
This lamp shows only the preset time. It has no sense for the operator.
            CURRENT STATUS RESET BUTTON (FIGURE 9)
RST button placed on two counters reset the current status, but since such use will be required very frequently, more functional buttons and latches are located on the control panel. Hence, such two buttons shall never be used.

            IMPORTANT REMARK FOR COUNTERS

            Counters are preset in relation with the technical requirements of the machine. Although counters are manufactured in order to be employed with other set programs for other uses, single set program is suitable for Double Spiral Automatic Chain Link Fencing Machine. This set program must never be changed. If the set button or 4.  Program button is pressed long, access to set program is established and current status display reads “outt” while desired final status display reads “1.3” If the set button re-pressed, current status display reads “Fr” while desired final status display reads “100”. These values of “1.3” and “100” are set program values which we have selected and they should not be changed. You can monitor this set program, which is impossible to change unwillingly, from the following table.

            Outt    - 1.3
            Fr        - 100
            Ar        - on
            Pr        - on
           

           

If you have come to doubt that set program has been changed somehow, you can check “outt” value by first pressing the 4. Program button for 1-2 seconds and Fr-100, Ar-on and Pr-on values, respectively by re-pressing the same button briefly three times. In the event the values have been changed, you should attain the same values by pressing the other program buttons. Accessing this program during operation is unnecessary and not recommended. All above information is entirely valid for the two counters. Counters are programmed so that they can substitute each other’s function.

           

They may be substituted for each other by changing the multiple plugs placed at the back of the main cover of the panel. Such features are conceived for the purposes of failure control.   

WIRE ADJUSTMENTS

For the efficient operation of the double spiral automatic chain link fencing machine, wire adjustments must be made. Once the wire adjustment is made, there is no need to interfere with the setting unless major change occurs in the raw material.
            Wire adjustment is made according to the two wires, which have advanced along knitting length inside the groove, but not cut yet. Two wires progressed on the lay-off arm inside the groove are stopped when approached to end of knitting length and then slow progress button is pressed once. For adjustment, wire must not be knitted on the slow progress button. Wire knitted on low revolution does not set forth accurate adjustment. Wire is knitted on the lay-off arm for adjustment. Wire adjustments consist of 5 sections.

1- VERTICALITY AT SHEAR MOUTH

Wires knitted but not cut must be VERTICAL AT SHEAR MOUTH. For appropriate cutting angle, a plane passing through one bottom and two peak points of the two wires must be vertical (90 degrees) to the machine table. If this setting is not correct, it can be made through stopping sensor angular adjustment arm (FIGURE 10). There is no need to remove any bolt in order to pull or push this arm. This is such a practical adjustment. Angular position change of the sensor provides us with this angular setting at a certain ratio. If such ratio is not sufficient for setting, i.e. if there is need for greater angular movement, main bearing toggle bolt is loosened (FIGURE 10). In such case, desired angular adjustment can be made since toggle will be free inside the bearing. After having made estimated angular adjustment, the desired fine adjustment can be made stopping sensor angular adjustment arm. If angular adjustment is to be made on the bolt, firstly, the main circuit breaker must be

2- VERTICALITY AT THE END OF KNITTING LENGTH

Wires that are knitted, have progressed along the knitting length (for instance, 1.5m), and not cut yet MUST BE VERTICAL AT THE END OF KNITTING LENGTH. Faulty status of verticality of two wires to two directions (inward and outward) at the end of knitting length is shown in FIGURE 15. Wire out of mould may lean inward or outward at the end of knitting length. Both faults seen in the figure may occur at the same time. These are not illustrated. There are two adjustments in order to rectify the verticality faults occurring at the end of knitting length. One of such adjustment (more practical one) is made through pulley jam arm (FIGURE 14). It is important to accurately determine from which pulley the wire with faulty verticality comes from in order to perform this adjustment (this is a very easy procedure if claws have been adjusted. If not, good monitoring must be performed). If the claws are not yet adjusted, trace is left on the wire by twisting with the help of a hand chisel immediately before the wire gets into the mould and this will facilitate the monitoring. After having determined the location of the fault, intervention is made with the jam arm of the pulley from which the faulty wire comes. Such interferences are indicated in FIGURE 15. As can be seen here, if the pulley jam arm is tightened (turned clockwise), lower tips of the wires lean inward at the end of knitting length. And if it is loosened then, tips lean outward. Tightening the jam arm means tightening the wire by lowering a bit upper three ball bearings of the recessed ball bearings (FIGURE 14). Reverse of this is the loosening of the wire. This is a very practical adjustment. Such tightness may be visibly monitored on the pulley dial plate. This adjustment method may not rectify major angular faults. Another adjustment method is to change lama twisting angle (FIGURE 11). Any small angular change affects the verticality at the end of knitting length. Pulley tightness has certain operational range. It is normal for the pointer on the dial plate to operate between units 5-2. It is not recommended to tighten the pulley for a unit that is more than 2. If the verticality is not ensured within such range, lama twist may be interfered. Twisting procedure may be performed in two ways. While lama is in the mould without being removed, one of the two twisting forks (FIGURE 12) is attached to lama from the right-hand side while other fork is attached to the lama from left-hand side and therefore, lama twist is interfered by strong and careful turn. Especially, lama twisting procedure may be performed by means of lama twisting apparatus (FIGURE 13) mounted on the chassis of the machine since the resistance of the lama would be great at larger spacing. Lama is removed from the mould for this procedure. When lama twist is interfered, verticality of the two wires at the end of knitting length will be changed.

Note: There is a very high tolerance in respect of the verticality of the wires at the end of knitting length. Especially, inward leaning of the wire is possible up to 30-35 degrees. This does not cause any knitting fault. In case of outward lean of the wire, no interference is possible up to 10-15 degrees. Once the wire verticality is adjusted, tightness of blue and yellow pulleys can be checked on the dial plate. When the wire coil is finished, pulley may be loosened when new wire coil is attached. After having attached the wire, pointer may be moved to the same tightness. Every now and then, it may be observed that verticality of the wires in wire knitting order can vary. Reason for this is the fluctuations in connection with the hardness and softness of potential wire. Machine shall proceed with the manufacturing unless such fluctuations cause any verticality fault to the extent that is beyond the tolerance. In case of exceeding the specified tolerance, adjustment can be made on the pulley by small interventions. Intervention with the lama twist is in question when in case of a major change as regards the specifications of the wire or replacement of mould. This is employed as the ultimate method. When lama twist is interfered for any reason then, main circuit breaker must be switched off.

3- PITCH ADJUSTMENT

 

Two wires that are knitted, progressed on the operation arm up to the end of knitting length and not cut yet MUST HAVE GOOD PITCH ADJUSTMENT. Pitch is the distance between the two peak points of the knitted wire (FIGURE 17). Accuracy of this adjustment means that peak points of the wire from the yellow pulley face yellow claws and peak points of the wire from the blue pulley face the blue claws. This case is clearly illustrated in FIGURE 16. Increase or decrease of the pitch of the blue and yellow wire during knitting can be seen in FIGURE 16 as well.

IMPORTANT NOTE: The most significant adjustment for high performance during wire knitting is the PITCH ADJUSTMENT. Location of claws is determined during changing the mould. Later, wires can be adjusted from the pitch adjustment drum depending upon the position of the claws.

           

4- ADJUSTMENT OF TIP TWISTING ANGLE

Further to the cutting operation, twisting angle of the blue wire’s tip that remains on the left MUST BE GOOD. During the cutting procedure, a twisting action is applied on the tips of both blue and yellow wires, which remain on the left (FIGURE 19). Such twisting action is specifically important for blue wire. It is necessary to twist backward the tip of the blue wire approximately 30 degrees. This angle can be increased or decreased on the upper twisting adjustment blot (FIGURE 20). There is a twisting mechanism inside the yellow wire tip, but such twisting is not so important for the knitting operation.

 

5- CENTERED CUTTING

Last adjustment to be taken into consideration for the purpose of attaining the wire knitting efficiency is CENTERED CUTTING adjustment. When wires are cut, length of the tips remaining on the left must be approximately equal to that of those remaining on the right (FIGURE 21). Position of the machine cutting mechanism is fixed and movement is provided for a centered cutting by a sled over molding and shaping mechanism. This movement is best achieved by 19 socket arms. The arm that will facilitate this procedure is provided with the machine. No bolt or nut other than this bolt should be loosened in order to ensure such movement.

              

CLAW ADJUSTMENTS

           There are two groups of claws with different height and length. These claws ensure the flow of wire by holding and releasing the wires, respectively. Claws must be adjusted during each mould changing. Among these claw groups, while there is a bi-directional (up-down, right-left) adjustment of the yellow claws (FIGURE 23), blue claws can only be moved in a single axis (right-left) (FIGURE 23). When the mould is changed, height of the yellow claws must first be adjusted. For this purpose, yellow claw height adjustment components that are attached on top of the groove (FIGURE 24) are used. One of these adjustment components is selected in conformity to the number contained on the mould inserted and such small part is inserted into the groove as shown in FIGURE 25 and yellow claw height adjustment bolt is loosened. Adjustment component selected subsequently is shifted in between the groove and claw. Yellow claw height adjustment bolt is tightened right after having dropped the yellow claw freely onto the adjustment component (height of the blue claws is never changed even if the mould is replaced).
            Afterwards, location of the claws on the shaft is fixed by shifting claws right-left according to the two wires that are adjusted in he groove, progressed up to the end of knitting length, but not cut yet. This procedure is performed as follows:
            Fixing bolt is loosened. This is performed starting from the two claws located at the leftmost side. Firstly, blue claw is shifted to the peak point of the wire coming from the blue pulley and then the fixing bolt is tightened. Following this, yellow claw is fixed to the peak point of the wire (wire coming from the yellow pulley), which is next to the fixing bolt. After that, claws, in turn, are adjusted in the same manner. Matters to be taken into account during claw adjustment:

a- First two claws are fixed starting from a place, which is the nearest to the shear (left).
b- There is no need to tighten the fixing bolts securely.

c- Wire adjustment control would be easier if claws are operated as one blue and one yellow claw without skipping any pitch in between (in twos)
d- Distance between the claw pairs must be equally distributed.
e- Yellow claws are adjusted to stick out 4cm from the groove. Blue claws should not stick out the groove (FIGURE 25).
f- Upon completion of the mould replacement, location of all claws can be checked once during mass production and small alterations can be made.
g- No claw adjustment is made until the next mould replacement. However, if the specifications of the unprocessed wire vary considerably even though there is no mould replacement or if the lama twist is interfered, claws can be readjusted.
       

IN-GROOVE HOLDING-UP ROD ADJUSTMENT

           This mechanism ensures that last wire knitted, cut and attached to the yellow claws stands fixed in the groove by supporting such wire from the front side (FIGURE 26). During claw adjustment or in case of any wire knot, rods must be pulled back, allowing the operator to respond to the inside of the groove. This is achieved through the in-groove holding-up rod (FIGURE 27). In-groove holding-up rod adjustment is made when wire is attached to the yellow claws. Firstly, rods are loosened from the fixing bolts. Arm takes the closed position of “b”. Fixing bolts are tightened by squeezing the rods slightly onto the wire with hand. While performing this adjustment, the first rod is fixed at a place nearest to the shear to ensure that first wire access would be more accurate.  Others are distributed to left and right with equal distances.

WIRE TIP HOLDING-UP MECHANISM ADJUSTMENT

           It is a component that is capable of moving inside the groove. It enables wires to change claws soundly and proceed further. It touches the right-hand side tips of wires progressed along the knitting length. For adjustment, firstly this mechanism is loosened and shifted to the right. Two wires are removed along the knitting length. This plate is squeezed by the drum at a place where it has slight contact with the wire tips when it is shifted from right to left (FIGURE 28).   

FIRST SCREWING

First access of wires (screwing) coming from the mould to the wire attached to the claws in the groove must be proper. In order to ensure this for every different mould and claw adjustment, the table to which the mould is mounted (FIGURE 29) is manufactured to allow such movement. If the knitting procedure does not materialize during the first screwing, i.e. if the wire gets stuck, the reason of this is searched for. For this purpose, operation arm is moved to the left (stop) after knitting and main circuit breaker is switched off. Main pulley is turned slowly with left hand and it is observed how wire tip proceed during first screwing. Mould is moved upward-downward (FIGURE 30) or inward-outward (FIGURE 29) to prevent such tangle. Adjustment bolts enabling such movement are seen in FIGURE 29 and FIGURE 30. There is no need to remove or loosen any other bolt to ensure such movement. It is enough to turn the adjustment bolts with 19 wrenches.

WIRE TANGLE STOPPING MECHANISM

It is a mechanism that stops the machine automatically in case of any deformation or tangle of the wire knitted due to any error or adjustment fault. If the wire knitted in the groove gets stuck or tangles then, shape of the wire is deformed and it hits the plate located underneath the lama (FIGURE 31). This plate has been designed to move even in a slight contact. Further to this, failure lamp is activated by means of wire tangle sensor. Simultaneously, machine stops automatically. It is necessary to rectify the problem and resume operation with the operator’s response. Position of the plate should be changed through the drum since lama’s measurement varies when the mould is replaced. Drum is manually squeezed, making an adjustment so as to leave a distance of 3-4 mm between the plate underneath the lama and the lama itself.

SPEED ADJUSTMENT

Wire knitting speed of the machine may be altered by changing the main motor pulley (FIGURE 32). On the other hand, cutting and tip-bending motor speeds are fixed. 4 speed adjustment pulleys are provided with the machine (FIGURE 33).
            Main motor is attached to the chassis with the help of four bolts and it can be shifted slightly through the ducts on the chassis. This movement is benefited during stretching the belt in case speed adjustment pulley is replaced.
            While changing the speed, belts are removed by manually turning the main pulley and pulley is attached again manually upon replacement. Tension should be so that main pulley can hardly be turned when belts are attached. If the tension is low then, loss in movement may occur. Belts and pulley should be protected against lubricants. If the tension is low, belts are removed and the motor is shifted backwards and then belts are attached again.
            During all this process, main circuit breaker must be switched off. It is possible to employ different pulleys other than this one in order to operate faster or slower. But this is not recommended.
            Selection of pulley has something to do with the efficiency. The largest pulley that ensures the highest efficiency must be installed to the machine. While deciding upon which speed adjustment pulley is installed to the machine, diameter and spacing of the wire is taken into consideration. In general, thin wires do not allow knitting at high speeds. The thinner the wire and larger the spacing, the smaller the pulleys selected. For example, 60-pulley should be used for a diameter of 2 mm with 8x8 cm spacing. 100 or 125-pulley should be used for a diameter of 2.8 mm with 5x5 cm spacing.
YOU CAN USE THE FOLLOWING TABLE

DIAMETER OF WIRE	SPACING
60         2 mm – 2,2 mm	60           10x10cm – 7x7cm
80       2,2mm – 2,5 mm	80             7x7cm – 4,5x4,5cm
100     2,2mm – 3,2 mm	100           6x6cm – 4,5x4,5cm
125     2,5mm – 3,2 mm	125           5x5cm – 4,5x4,5cm

 

ELEVATION CHOCKS

           Elevation chocks are supplementary apparatus used for knitting wires in the same groove with different spacing. There are two types of elevation chocks (FIGURE 34).
            Thick elevation chocks with a spacing of 4,5x4,5 cm or thin elevation chocks with a spacing between 5x5cm and 6,5x6,5 cm are used. No other elevation chock having spacing greater than 6,5 cm is employed. Elevation chocks are placed freely in the groove so that their larger surfaces remain on top (FIGURE 35). They are placed in the groove with several cm intervals. 5 pieces of chocks of each type are provided with the machine. Appropriate number of chocks conforming to the wire knitting length is manually placed within the groove.   

           

 

HEADPIECE ADJUSTMENT

           There are two headpieces on the machine table, one being on the right and the other one being on the left (FIGURE 36). Headpiece on the right may be shifted on the machine table in case the fencing width has been changed. For this purpose, headpiece fixing Tees are removed. Later, rectangular bearing Tee is loosened. Afterwards, headpiece is pulled to the right or left and Tees are attached again where appropriate. If headpiece fixing Tees are not removed, but just loosened then, headpiece may displace about 8-10 cm owing to the ducts existing thereon. If the amount of movement is not sufficient, Tees are not removed, but just loosened. It may be necessary to slightly approach or farther the bending apparatus to the wire during wire tip bending process. It may also be necessary for the left headpiece to shift several cm when mould is replaced. There is no need to securely tighten the Tees.

ADJUSTMENT OF BENDING MECHANISM

There exists bending mechanism for the purpose of bending the open wire tips that have been knitted on the headpiece (FIGURE 37). When mould is replaced, bending apparatus sled must be adjusted by shifting on the headpiece. Firstly, bending apparatus sled fixing Tees are loosened. Later, motion arm of the bending apparatus sled is turned with hand to shift it to the desired place and Tees are tightened again. After length alteration process, only the right apparatus needs to be adjusted. Place of the left apparatus does not change. There is no need to securely tighten the Tees. 

WIRE FLOW STOP MECHANISM

Sometimes, the wire coming from the coil is irregular and this causes wire to the pulley to stress by lifting up the wire loading weight. In this case, a mechanism that is shown in FIGURE 38 stops the machine with the help of a stop switch and then error lamp lights on. Since wires of different diameters can be knitted in the machine, spring power exerted on the stop switch must be changed depending upon the diameter of the wire.
            When the amount of thin wires increases, one or two out of three stop switches should be disconnected (one of the springs in FIGURE 38 is not in use). For this purpose, the following table can be used.

2mm – 2,3mm         1 spring

2,2mm – 2,7mm         2 springs

2,5mm – 3,2mm         3 springs

                          
NOTE: If this mechanism unnecessarily stops the machine even if there exists no irregularity in the wire flow then, number of springs should be increased. If the machine cannot stop or stops late despite the fact the wire is stressed much due to irregularity then, number of springs should be decreased.

 LAMA CORRECTION ADJUSTMENT

          Lama plays the most important role in shaping the fencing (FIGURE 11). Deformation of this component adversely affects the knitting process. Especially, two types of deformation seen in FIGURE 39 cause the knitted wire to leave the mould to form an arch instead of being flat. It is pretty hard to see the deformation since the lama moves inside the mould. Instead, deformation can easily be spotted if the wires coming out of mould are checked. Two wires are knitted in the groove and wires are placed on a flat ground by cutting manually. If the line connecting the folded points of the wire forms an arch then, lama is considered to have been distorted. Especially, if a wire of 2,3 mm or thinner is knitted, such deformation must be rectified. If there seems to be no arch when two wires are put on an even surface then, it would be wrong to interfere with the lama. Visual control of the wire is more important than visual control of the lama.    
            Other type of lama deformation is illustrated in FIGURE 40. This is a very rare kind of deformation. In any occurrence of such incidence, either the deformation should be rectified or another lama should be installed.
            In another lama deformation, a wearing over time can be possible at places where lama first touches the wire (FIGURE 41). Petty deformations do not cause any deformation in knitting, but in further stages, it is harder to obtain proper wire from the mould. Although such deformation can be rid of by good workmanship resulting with the welding of the deformation, it is recommended to replace the lama.
            First two deformations may be rectified with the help of a hammer upon visual inspection. Lama correction adjustment discussed above is different than the adjustment necessary for changing the lama-twisting angle discussed in the section of wire adjustment. Interference contemplated herein is rarely required. Interference with the lama twist is a compulsory adjustment required time after time even though it is not desired.

MOULD DEFORMATION

Sides of the mould may be worn out to the extent that prevents the proper wire production after a lengthy operation period. Wire intended to be knitted can get stuck between the mould and lama and wire cannot be given shape. In such case, lama deformation is doubted at the first points of contact (FIGURE 41). If there is no problem with the lama, the mould can be removed and inspected visually. Mould is changed if excessive wearing is observed in areas shown in FIGURE 42.

FIRST STARTING AND PUTTING THE MACHINE IN AUTOMATIC OPERATION

1- Open the section on the back of the machine and take out the tools and apparatus.

2- Install the wire loading poles (both poles shall be attached to the chassis by means of four bolts)

3- Check the rotational direction (it should be clockwise)

4- Attach the belts.

5- Fill the tank with Boron Oil (one unit of oil should be mixed with ten units of water).

6- Ensure that Boron oil flows from the two valves by switching on the main circuit breaker.

IMPORTANT NOTE: After having taken out the tools and apparatus from the back of the machine and attached the poles, proceed with operation for a while without replacing the mould. Unless it is very compulsory, do not interfere with any bolt or electric connection.

 7- Switch off the main circuit breaker (position "o"). Move the lay-off arm to "left" (stop).

8- Put the wire coils so that they are right beneath the wire loading weights. Put the baskets right in the middle.

9- Pass two wires through the wire loading weight, wire loading pulley and control rings.

10- Loosen the pulleys by the pulley jam arm.

11- Pass the wires first inside the wire control ball bearings, then wire control fork and finally, among the ducted ball bearings.

12- Pass any of the wires through the wire control point (small ball bearings) and attach it to the lama by forming a small hook made with a chisel.

13- Open the main pulley housing. Turn manually the main pulley toward yourself. Ensure the tip of wire proceed one revolution in between the lama and mould duct.

IMPORTANT NOTE: Before manually interfering with the main pulley, ensure that the main circuit breaker is switched off.

14- Repeat the same process for other wire.

Switch on the main circuit breaker by taking the wire chisel and your hands away from the mould.

16- Advance the wire until the mouth of the shear by pressing the slow progress button several times.

17- Tighten both pulleys until the pulley dial plate reads "3" ("3" is an approximate, average pulley arrangement. Such arrangement may vary depending upon the wire diameter and hardness)

 

18- Equal the tips of wire by cutting through wire chisel from the same point (Manual cutting operation should be performed at one bottom and one peak point of the knitted wire)

19- Advance the wires for several revolutions through slow progress buttons.

20- Using a chisel, make a backward opening with the tip of wire coming from the blue pulley (such operation should not be performed at the mouth of the shear for your own safety)

21- Advance the wires from the lay-off arm until a place close to the end of knitting length with short movements. Complete the last two revolutions with slow progress button.

Check the "VERTICALITY" and "PITCH" adjustments of the wire that advanced until the end within the groove and is not yet cut. Refer to the "wire adjustments" section for such adjustments.

23- If the adjustments are good and proper, move the manual-automatic latch to position "o" and press the cut-off button.

NOTE: If the cut-off button is pressed briefly, cutting process may not be materialized. You may need to switch on and off the manual-automatic button before pressing again. If you keep the cut-off button pressed long, cutting process takes place twice successively and this prevents the knitting process) Press CUT-OFF BUTTON for a period of 1-2 seconds.

24- Move the lay-off arm to the "right" (start) position.

25- Your machine will start running. Unless there exists an external factor, it will continue working automatically.

PRIORITY ISSUES FOR HIGH EFFICIENCY

• 1- Check the pitch adjustments Do the peak points of the wire coming from the yellow pulley face yellow claws and do peak points of the wire coming from the blue pulley face blue claws?
• 2- Check the twisting adjustment. Is there a twisting of at least 30 degrees on the tip of wire coming from the blue pulley?
• 3- Check the verticality at the mouth of shear. Are wires vertical to the mouth of shear?
• 4- Check the verticality at the end. Are wires vertical at the end of knitting length?
• 5- Check the centered cutting adjustment Are wires cut in the middle?
• 6- Check the consistency of the Boron oil. Does water flowing from the valves have a lubricant feature?
• 7- Check the raw material softness-hardness variation. Is there any hardness difference when the wire entering into both pulleys is bended or is it possible that some portion of the wire coil is soft while the remaining portion is hard? If you have come to doubt as regards the hardness fluctuations, change the wire coil and make a readjustment.
• 8- Check the speed adjustment. As the diameter of wire decrease and spacing gets larger, machine is operated on low revolution.
• 9- Check the lama deformation. Does rounded part of the lama have good linearity?
• 10- Check mould deformation. Are sides of mould worn out?
• 11- Check other possible deficiencies and remedies?
• 12- If all such controls have been performed without any success, pitch adjustments are made so that wires can pass through the middle of the mould's mouth. Pulley arrangements of 7 is entered as "3"

DURING MODIFICATION OF LENGTH

A -ENLARGING THE LENGTH

1- Drum of the wire tip holding-up mechanism is loosened and plate is shifted to right.

2- Machine is moved to position "e" through manual-automatic latch.

3- Two wires are advanced inside the groove along desired knitting length.

4- Wire tip holding-up plate is adjusted (shifted to left).

5- If deemed necessary, in-groove elevation chock is used.

6- Desired amount of claws are set for the lengthened part of the wire knitting.

7- Fencing height counter is set.

8- Desired amount of starting weights are attached on the lengthened part of the wire knitting.

9- Right cap and wire stretching apparatus are appropriately slid on the table (FIGURE 43).

10- Table heightening bars are set.

11- The machine is run in automatic position.

12- Right tip sled is set if required.

       

B- SHORTENING THE LENGTH

1- The wire stretching apparatus are slid to appropriate positions on the table.

2- Table heightening bars are set.

3- The machine is moved to "e" position and the wire is knitted in the required length.

4- The claws at the shortened part of the wire knitting length are loosened.

5- Fencing height counter is set

6- Wire tip holding-up arrangement is shifted to left and set by loosening the drum.

7- The machine is operated in manual or automatic mode until the long wire is fall down the back side by sliding on the table. /p>

8- The cap at right is set.

9- Right tip sled is set if required.

DURING MODIFICATION OF MOULD

1- The main switch is turned off.

2- Lama is removed by removing a single bolt.

3- Mould removed from its clips by loosing four bolts.

4- The sled is positioned to meet the shape of desired mould by using forward-back setting bolt. Appropriate positions of the moulds on the sled are printed on the metal surface.

5- The mould for intended mesh space is placed in the claps. There are separate special marks on each of the claps and the mould for the position of the mould. The position at which these two marks are coincided is the appropriate connection position of the mould. These two marks are aligned and four bolts of the clips are tightened. (It is not necessary to tighten these four bolts too much).

Lama is placed into the mould. The lama is rotated one or two tours in the mould. If the lama rotates freely then it is attached to the joint of lama with a single bolt. If it does not rotate freely then the reason of this problem is tried to be found. It is required to correct the problem and replace the lama. (It is not necessary to tighten this bolt too much).

7- Wire tangle plate is adjusted.

8- Appropriate elevation chocks are placed into the groove.

9- The previously knitted fence is removed from claws and then from the machine.

10- Wires from the yellow and blue reels are attached to the mould.

11- Two wires at the knitting length are removed and their adjustment is checked.

1. a. Wires are perpendicular to the shear mouth
2. b. Wires are perpendicular at the end of knitting length.
3. c. Pitches of two wires should be equal to each other.

12- Appropriateness of adjustment of the centered cutting is visually checked. It is re-adjusted and rechecked If it is not appropriate.

13- Claws are adjusted.

14- Wire tip holding-up plate is adjusted.

15- Knitted wires are cut at the shear mouth by manual cutter. (FIGURE 44)

16- Two cut wires are attached to the claws with initial weights at such position that the knitted wire from the blue reel will be at the upper position.

17- Twisting at the tip of wire from the blue reel is made by hand cutter. Wires are progressed by starting up lever until the end of knitting length. Wires are cut by machine, pressing on the cut button.

18- Twisting adjustment is controlled. Twisting is increased or decreased if required.

19- Positions of both twisting arrangement are adjusted.

20- Fence height counter is adjusted.

21- Roll length determining counter is adjusted.

22- Wire adjustments, claw adjustments and twisting mechanism adjustments are checked once more and the machine is set to automatic running.

POSSIBLE UNPRODUCTIVENESS, FAILURES AND SOLUTIONS

1- WIRE JAMMED OR LOOSENING

Knitting is performed by screwing the wire from blue reel on the knitted, cut and ready wire in the groove. At the same time, it is required to attached the wire from yellow reel to the ready wire. If there is a problem for knitting there may be three problem conditions.

• a- WIRES JAMMED AT THE FIRST MOUTHING (INLET)

For solution the machine is stopped before starting to screw wires. Main switch is turned off. While rotating the main pulley with left hand, screwing of wires to the wire in groove is carefully observed. If this inlet is not correct; for example; the wire from blue reel is screwed to the wire in groove at too low position or not screwed at all, then get it is elevated by using up-down adjustment bolt. If the wire from the yellow reel is run too close to the ready starting wire or even touching it the mould is lowered by using the same bolt. Similarly if the wire from blue reel is attached the ready starting wire from too outer position then it is moved inside by using in-out adjustment bolt.

• b- BOTH WIRES LOOSEN IN THE GROOVE

If the blue wire is loosened without screwed to the ready wire in the grove, the solution is to lower the yellow claws a little bit. Especially if the wires are loosen out at the same point then lower one or two claws one a few millimetres and re-observe the situation.

• c- WIRE FROM THE YELLOW REEL JAMMED TO THE READY WIRE IN THE GROOVE

For solution, it is recommended to elevate the yellow claws a little bit. If such jam is especially at the same areas then elevate one or two claws a few millimetres and re-observe the situation.

NOTE: For the above mentioned three positions, first of all the wire adjustments should be controlled. Then, these recommended operations could be performed. For the first two conditions, the first solution to be tried is to increase the twisting.

INCOMPLETE CUTTING AT THE LAST TOUR OR WIRE STRIKING THE HOLDING-UP PLATE AFTER A LONG CUTTING

 strong>Last half tour of the machine is performed by the auxiliary engine completing last incomplete tour after free stopping of the main engine. After each cutting process, this small movement should be observed. This movement of the auxiliary engine is to correct angular defects arisen from the inertia of main pulley. The operating principle is to move the tour counting ear on the main shaft in front of the stopping sensor regardless of the position of auxiliary engine after stopping the main engine at any angular position. By this way main shaft and thus knitted wires always stop at the same angular position, which is necessary for a correct cutting procedure. In this design however, there is a deficiency. If the main engine and thus main shaft are accidentally stopped when the full tour counting ear is in front of the stopping sensor then the auxiliary engine is out of order. Therefore, pre-cutting small angular position differences could be observed. To correct such unwanted situations the counting sensor is placed in a groove in such a position to let an angular movement independent of the stopping sensor. In short, if the auxiliary engine is not operated at the end of wire knitting then the position of counting sensor is changed to put it into operation. If the last tour is observed to check if the auxiliary engine is operated, it could be seen at the left shaft of the auxiliary reductor. This situation is also characterized by a one more or less last tour during the automatic knitting. If the wires run an half tour more and strike the wire holding up plate sometimes, first of all the counting sensor is moved to left. (FIGURE 43) If it is not sufficient, bronze breaking lining is tightened by screwing the tightening-loosening bolts one or two tours. (FIGURE 46) If the wires are an half tour short at the last tour sometimes the counting sensor is moved to right. If it is not sufficient then the bronze plate is loosened by loosening the tightening-loosening bolt one or two tours.

3- FAILED ENGINES EXCEPT THE WATER ENGINE

         It is related to the thermal relay (FIGURE 47). This relay protects 4 engines other then the water engine in the machine against heating and burning due to over loading. Under normal conditions machine engine powers are suitable for 24-hour operating. If one of the electrical phases from the network is failed due to any reason the engines are over loaded. Then the thermal relay opens the circuit and cut the electricity to the engines. Such overloading conditions could rarely be caused by mechanical reasons.

            If the water engine is operating but other cutting, slow running buttons and starting up lever are not operable and the warning lamp doe not light, it means that the thermal relay cut the electricity by opening the circuit due to overloading condition on the engine.

            In this case, firstly main switch is turned off. Panel cover is opened and “reset” button of the thermal relay connected to one of the contactors in the panel (FIGURE 47). If the engines start to run after turning on the main switch, production is continued. If this problem is repeated within a short period of time, the reason of the problem is searched. First of all, it should be carefully examined by an electricity technician if one of three phases is failed or not.

4- IF THE SHEARS DO NOT CUT WIRES

If the shears do not cut wires although they are moving, first of all it is suspected if THE LENGTH OF COURSE IS INSUFFICIENT. In other words, it is possible that the blades of shears do not meat each other sufficiently during cutting. In such cases, especially shear cam following bearings is controlled. If the bearing are not failed then the bolts of such bearings, follow-up lever joint bolts and pin bolts are checked (FIGURE 48). These bolts are tightened if they are loosen. The baled of shares are checked for any breaks or blunts. If there is not any break or blunt and you are sure that there is an insufficient length of course, then you may weld a very thin filling (1-2 mm) on the surface of the shear cam as showed by the FIGURE 49.

            In a second condition, the blades of shears are meet each other appropriately but the wire is jammed between wheels and not cut especially for thin wire diameters. Or shear arms could also be jammed. This may be caused by any increased distance between the rear cutting blade and support component of cutting blades. Front shear blade is removed and inserted between these two parts to check the space. If there is a large space, first of all two bolts connecting supporting component and rear blade are checked. If these two bolts are tight, the support component is removed and surface grinded and replaced to decrease the space.

            After each intervention, first of all springs are removed and arms of shears are manually get closer to each other and it is observed if the blades meets appropriately. 

NOTE: Above mentioned welding and grinding procedures are unwanted solutions and are rarely preferred. Please hesitate such interventions unless being certainly sure about the condition.

5- BORON OIL NOT FLOW

If the boron oil does not flow from both taps, then the boron oil pump (water pump= may be burned (FIGURE 50). For this, the cover of boron oil chamber is removed and the pump is checked by an electrical technician. Pump engine is changed if burned. The reason preventing the flow is corrected.

SAFETY RULES

1- Nobody is allowed to be enter under the machine when it is the elevated during the loading-unloading,

2- It is not allowed that two persons are working at the same time on the machine.

3- In case that the boron oil is overflow due to any reason, measures must be taken to prevent it make the working are of the operator be slippery.

4- It is recommended to work with gloves.

5- Electrical connections on the machine may only be intervened by an electrical technician.

6- Rotating parts are not intervened unless turning off the main switch.

7- Operator may not intervene at the mouth of shears.

8- Twisting mechanism may not be intervened without turning off the main switch.

9- If the lama twisting angle is changed on the machine, the main switch should be turned off.

10- Cover of the panel must be closed during the operation.

11- Manually cut wire pieces should be removed from the floor on which the operator works.

12- When the belt is removed the main switch should be turned off.

13- Before the panel is opened the main switch should be turned off.

 

OPERATION MANUEL

AUTOMATIC CHAIN LINK FENCING MACHINE

MODEL ADF3

 

MANUEL