Perfect Manufacturer in China of CNC Header Pipe Drilling Machine Djx3512 for Pressure Vessel Boiler

• Customization: Available
• After-sales Service: Lifetime Service
• Warranty: 12months
• Model NO.: DJX3512
• Structure: Horizontal Drilling Machine
• Layout: Horizontal
• Controlling Mode: CNC
• Number of Shaft: 5
• Hole Diameter: <50mm
• Automatic Grade: Automatic
• Precision: High Precision
• Certification: CE, ISO 9001
• Condition: New
• Pipe Materials: Carbon Steel (20g, SA-106c, etc.) Alloy Steel (15c
• Outer Dia. of Header Tube: 100-350mm
• The Thickness of Header Tube: 5-60mm
• The Length of The Header Tube: 2-15m
• Weight of Header Tube: Less Than 20t
• Drilling Diameter: 3-50mm
• Accuracy Between Any Two Holes: +-0.3mm
• Transport Package: Suitable for Export Transportation
• Specification: pipe diameter 100-350mm
• Trademark: SAFETY
• Origin: China
• HS Code: 8459210000
• Production Capacity: 12 Per Year

Product Description

                                                    CNC Header Pipe Drilling Machine DJX3512
 

1.Application:This machine is primarily used for drilling header-type tube hole in the boiler industry. It can automatically complete drilling, boring, spot facing, milling, and other processes in one operation. Using this machine the manual scribing, marking, and other auxiliary tasks needn't, significantly improving the precision and efficiency of workpiece processing and shortening the production preparation cycle.

2.Overall description of the machine
The drilling and milling machine is a flexible CNC machine with complete functions, advanced system, and high degree of automation. It meets the needs of various batch production and realizes civilized automated production, which is in line with the trend of intelligent development of modern factories.
This machine has a square type gantry and a single drilling and milling power head structure, with complete and reliable safety protection, and a beautiful appearance. The equipment selection is reasonable, the manufacturing is excellent, the performance is outstanding, the accuracy is stable, and it has good static, dynamic, and thermal stiffness, suitable for long-term, continuous, and high load processing; The operating interface is simple, intuitive, and smooth. The whole machine has stable performance, reliable operation, and easy maintenance. Design and manufacture in compliance with national safety and environmental standards.

3. The Main Structure and Characteristics: For ease description, the specific definitions of each operation axis and direction are as follows: the gantry moves along the length direction (longitudinal) of the header as the X-axis (X1 axis and X2 axis), the indexing head moves along the length direction (longitudinal) of the header (or machine tool) as the X3 axis, the drilling and milling power head moves along the span direction (transverse) of the gantry crossbeam as the Y-axis, the XY axis is perpendicular to each other in the horizontal plane, the vertical movement direction of the drilling and milling power head is the Z-axis, the Z-axis is perpendicular to the XY horizontal plane, the indexing head chuck rotates as the A-axis, the A-axis rotation axis is parallel to the X-axis, and the spindle rotation is the SP axis. The operator standing in the operating room of the host facing the workpiece is considered to be in front, and vice versa, and the front to back direction is also the Y-axis transverse direction; The left and right sides are the length direction of the container (or machine tool) (X-axis longitudinal direction), and the indexing head chuck clamps the workpiece with the head end located on the left side of the host and the workpiece tail end located on the right side of the host.

The machine mainly consists of a bed body, CNC dividing head, gantry and sliding plate, drilling and milling power head, workpiece support and clamping device, pressing device, header length and tee end face alignment device, header bending measurement system, cooling system, chip removal, lubrication system, pneumatic hydraulic system, control system, as well as tool magazine, tooling and cutting tools. Its structure and characteristics are as follows:

3.1 The bed, gantry, slide saddle, and power head slide pillow are widely made of high-quality castings, which have good seismic performance and are conducive to maintaining the stability of mechanical performance.The bed frame is the basic component of the machine tool, which is made up of multiple sections of bed frames that are connected together. The bed frame is treated with overall thermal aging to relieve stress and has good rigidity and stability Two bed frames are arranged in parallel and vertically, with two high load-bearing linear rolling guide pairs arranged on each bed frame for guidance. There is a large modulus rack and a set of grating rulers for positioning and detection in between.
One set of longitudinal sliding tables is installed on the bed guide rail pair to support the gantry. Each sliding table is equipped with an AC servo motor that drives the clearance reduction helical gear to move longitudinally (X-axis) on the meshing rack through a precision reducer. The double-sided motors synchronously drive the sliding table (gantry) to move longitudinally (X1 axis and X2 axis). The X-axis adopts a grating ruler closed-loop detection, with high positioning accuracy.
The machine tool reserves a gantry parking space, allowing for vertical lifting of 18m workpieces.The gantry column is installed on top of two bed slide tables, and the single gantry frame is an integral structure that adopts integral thermal aging stress relief treatment, with good rigidity and stability.

3.2 The gantry adopts a double door square type gantry structure, which has sufficient rigidity and smooth operation, which is conducive to ensuring the machining quality of workpieces and the service life of cutting tools.

The longitudinal movement of the gantry (X axis) is guided by four straight rolling rails (two rails on each side) fixed on the bed, providing flexible movement. The drive adopts two AC servo motors, which are synchronized on both sides through precision reducers and large modulus anti backlash helical gear and rack pairs. The gear and rack have anti backlash mechanisms.

The cross-section of the gantry crossbeam is L-shaped, and the guide rails are installed on opposite sides of the upper and front sides. Each crossbeam is equipped with a precision roller guide pair on the upper and front sides of the inner side. The gantry has a reasonable load-bearing structure, good shock absorption effect, and stable performance.

3.3 The Y-axis skateboard (saddle) is installed on the crossbeam and serves as the mounting base for the drilling and milling power head slider.
Two horizontal beams are installed in parallel and symmetrically arranged, with two high load-bearing linear rolling guide pairs arranged horizontally on the inner side of each beam for Y-axis guidance. The four sets of guide pairs on the two horizontal beams are equipped with a set of horizontally moving sliding saddles for installing the power head slider (Z-axis), which are driven by a servo motor through a precision planetary reducer to drive the Y-axis screw pair to move laterally.
3.4 The drilling feed is controlled by servo, and the feed stroke can be automatically memorized. Not only is the drilling efficiency high, but the accuracy is also high. When the drill bit quickly approaches the workpiece, it automatically switches to work in, and rapid feed automatically switches to work in. After the workpiece is drilled through, the drill bit quickly retracts. It can greatly save auxiliary time, so the machining efficiency of this machine is high;
The power head also has the functions of graded feed and automatic chip breaking. The blind hole depth and chamfer size can be processed arbitrarily, and the consistency during countersunking is good

3.5 The drilling and milling power head adopts the BT50 precision internally cooled spindle produced by a professional manufacturer. The spindle taper hole has a butterfly spring automatic tool pulling mechanism, hydraulic loosening tool, and automatic blowing to clean the spindle inner hole. It has tool tightening status monitoring and safety interlock protection, making replacement safe and easy.

3.6 The workpiece achieves rotational indexing through precision rotary bearings on the CNC indexing head. The CNC dividing head is installed on the longitudinal sliding plate at the left end of the machine base, and the X3 axis servo motor drives the screw pair to drive the sliding plate to move longitudinally, with accurate positioning and convenient processing and loading and unloading of the collection box.
The motor drives the ball screw pair lifting chuck through the reducer, and moves up and down by 200mm stroke. The center position of the chuck can be adjusted vertically and can freely float up and down for buffering, facilitating the clamping of workpieces of different diameters. The chuck can also float up and down with the change of the position of the header end, reducing the damage caused to the chuck by the additional force generated during the rotation of the header.
3.7 The workpiece support is mainly used for the support and clamping of the collection box, evenly distributed on the track. It is driven by a hydraulic motor installed on the support slide to rotate the gears and move longitudinally (X-axis) on the meshing bed rack. The moving speed is adjustable for easy support arrangement.
3.8 The machine is equipped with a pressing device, which is used in conjunction with the workpiece support to securely fix the header and prevent vibration during the cutting process.
3.9 Non contact laser measurement sensors and contact mechanical measurement devices are installed on the gantry and power head of the machine tool, which can achieve the alignment of the tee end face before processing, the measurement of the header length, the measurement of curvature, and the measurement of the deformation of the hole position workpiece during the processing to ensure the accuracy of groove processing. For specific introduction, please refer to the electrical system description later.
3.10 There is 16 piece bucket hat style intelligent tool magazine installed behind the gantry, which can achieve fast and accurate automatic tool changing without human intervention, reduce the labor intensity of workers, and achieve civilized and efficient automated production. The tool changing system has high stability and extremely low failure rate. After long-term operation, it can continuously and accurately change tools, avoiding the phenomenon of tool changing or dropping due to factors such as inadequate tool taking devices.
3.11 The machine is equipped with two sets of hydraulic systems, one set installed on the gantry, mainly controlling the hydraulic actuators that move with the gantry, such as cutting, weight balancing of the power head, sliding saddle and gantry locking, and material pressing; The other set is installed on the ground and mainly controls other hydraulic actuators, such as workpiece support movement, workpiece support frame lifting and clamping, chuck floating, etc.
3.12 The internal and external cooling pumps of the machine tool cooling system work independently, and the internal and external cooling can be supplied separately or simultaneously without the need for manual switching. The sprayed coolant flows back into the coolant tank through the accumulation tank, and the coolant can be recycled. Equipped with a filtering device and a high-pressure water gun to facilitate the cleaning of iron filings from the supporting device.
3.13 The stainless steel chain plate chip conveyor is placed under the support base between the two bed frames, and discharge the iron chips into the iron chip box.
3.14 The equipment adopts two sets of centralized automatic lubrication systems, one set installed on the gantry, mainly lubricating the points that move with the gantry, such as X1, X2, Y, Z-axis guide rail pairs and screw pairs, guide rods, etc; Another set is installed on the dividing head, mainly to lubricate the nearest points of the dividing head, such as the rotary support ring gear, X3 axis, chuck lifting guide rail pair, and screw pair.
3.15 The electrical system is based on the Siemens 828D system (control unit PPU290) to control the operation of the machine tool, achieving dynamic monitoring of human-machine dialogue, program programming, storage, and operation; The automatic control of fast forward, work in, fast backward drilling and its auxiliary operations has greatly improved the precision, efficiency and reliability of drilling processing. All CNC axes are controlled by Siemens S120 drive system (including motor), equipped with ALM adjustable power module with AIM interface and Siemens handheld unit as standard; The XY gantry axis adopts Heidenhain grating ruler for full closed-loop detection.
The system features an LCD display and a user-friendly interface, with functions such as human-machine dialogue teaching, counting of workpiece processing quantities, error compensation, multi axis interpolation, power-off protection and power-off memory, real-time dynamic detection and processing of tool breakage, tool life management, automatic alarm, real-time monitoring, remote diagnosis, etc. It is also equipped with CF card interface, Ethernet interface, and USB interface.
The entire drilling process has achieved computer numerical control monitoring and automation control.

Main technical parameters:

Item	Description	Parameter
Size of header tube	Materials of header tube	Carbon steel (20G, SA-106C, etc.) Alloy steel (15CrMoG, 12Cr1MoVG, SA-335P91, SA-335P92, etc.)  Stainless steel material (SA-312TP321H, 12Cr18Ni9Ti, 316L, etc.)
	Outer dia. Of header tube	Φ100~φ350mm
	The thickness of header tube	5~60mm
	The length of the header tube	2~15m
	Weight of header tube	≤20t
	Drilling diameter	φ3~φ50mm
	Max.rotation dia. Of header tube	Φ380mm
Processing method and accuracy	Processing method	Using specialized clamp type cutting tools (hard alloy blades), drill through the hole first, then change the tool to process the bowl shaped hole, or use a socket drill for processing.
	Accuracy of spacing between any two vertically adjacent holes	±0.1mm
	Deviation of center distance between any adjacent pipe holes in the circumferential direction	±0.5mm
	Accuracy of spacing between any two vertical holes	±0.5mm
	Deviation of spindle feed rate (Deviation in groove depth)	±0.3mm
	Pipe hole roundness	≤0.05mm
	Surface roughness of drilling holes	≤6.3μm
	Dimensional accuracy of drilling holes	IT11~IT12
CNC dividing head	Quantity	1
	Chuck form	Self centering hydraulic chuck
	Self centering four jaw chuck diameter	φ550mm
	Center high adjustable itinerary/mode	±100mm/Jog
	Vertical moving motor power	2.2 kW
	Travel along the X-axis direction	≥1000mm
	Rotary motor power	≥10kW
	Rotary speed	0~4r/min(with CNC)
	Division positioning accuracy	2.5′
	Repetitive positioning accuracy of division	1.5′
	Vertical feed rate mode	Jog
	Horizontal feed rate mode	Jog
Drilling head and  vertical slide table	Quantity	1
	Tipper of spindle	BT50
	Power of spindle motor	≥37kW
	Max.torque of the spindle	800Nm
	Speed of spindle	30~3000 r/min
	Stroke of axis-Z	≥400mm()
	Stroke of axis- Y	≥200mm
	Max. Speed of aixs- Z	5000mm/min
	Power of axis-Z	≥3kW
	Max.speed on direction axis-Y	10000mm/min
	Motor power on axis-Y	≥3.1kW
	Accuracy on axis-Y/Z	0.03mm/Total length
	Repeat accuracy on axis-Y/Z	0.02mm/1000mm
	Driving way	Servomotor +ball screw
Gantry on axis-X	Quan. Of gantry	1
	Driving method	+
	Max.stroke on axis-X for gantry	≥15m
	Max.speed on axis-X	10000mm/min
	Motor power on axis-X	4.2kW×2
	Accuracy on axis-X	0.15mm/
	Repeat accuracy on axis-X	0.01mm/1000mm; 0.08mm/Total length
Support	Lift support	4pcs
	Fixed clamping support	7pcs
	Floating support	3pcs
	Manual lifting support	6pcs
	Lift stroke	400mM
Tools magazine	Type/quan.	bamboo hat/1set
	Tools quantity	8
	Model of tipper	BT50
CND system	quantity	1set
	Model	Siemens 828D
	Quantity of CNC axis	4+1(4pcs feeding axis,1pcs spindle)
Hydraulic system	quantity	2sets
	Pressure/flow	3~7MPa/16.7L/min
	Power of motor	2.2kW
Cooling system	Inner cooling pressure/Flow	5MPa/70L/min
	Power for inner cooling pump	7.5kw
	Power for outer cooling pump	0.75kW
Lubrication system	Mode	Manual+Automatic
	Automatic system	2 sets/Oil injection cycle and oil quantity can be digitally programmed
Chip remove conveyor	Type	Plate-chain
	quantity	1set
	Power of motor	2.2kW
Total power		120kW
Dimension(L×W×H)(m)		20×6.5×6m
Working input voltage		Three-phase four-wire   AC380±10%V    50±1HZ
Control input voltage		AC220±10%V    50±1HZ

,Main component manufacturer

No.	Name	Brand	Country
1	Leaner guide way	HIWIN/	Taiwan, China
2	Drilling spindle	Kenturn	Taiwan, China
3	Ball screw	I+F/NEFF	Germany
4	CNC system, servo system, handwheel, DC stabilized power supply	Siemens 828D	Germany
5	Servo motor	Siemens	Germany
7	X-axis gear rack pair	ATLANTA/	Germany/Switzerland
8	Precision dual speed gearbox	ZF/BF	Germany/Italy
9	Hydraulic valve	ATOS/	Italy/Germany
10	Oil pump	ATOS/	Italy/Germany
13	Electrical component	/	Germany/France