Reflex GX616 User manual

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  
Model No.: REFLEX-FASTFORM- GX616
OPERATION MANUAL
ORIGINAL

INSTRUCTION
REBAR STIRRUP
BENDINGMACHINE
REFLEX FAST FORM GX616
CNC

CATALOGUE
1.Product description......................................................................................................................................................... 3
1.1. Features of this product:....................................................................................................................................3
1.2. Main purpose and scope of use....................................................................................................................... 4
2.Structural features and working principle....................................................................................................................4
2.1. Mechanical structure features and working principle:.................................................................................. 4
2.2. Electrical structural features and working principles.....................................................................................6
3. Technical characteristics............................................................................................................................................... 7
3.1.The main technical parameters of the equipment..........................................................................................7
3.2. Overall dimensions and installation dimensions........................................................................................... 8
3.3. Main features.......................................................................................................................................................8
4. Installation and debugging............................................................................................................................................9
4.1. Equipment installation conditions, installation technical requirements......................................................9
4.2. Installation and debugging methods and matters needing attention......................................................... 9
4.3. Before trial run, trial run..................................................................................................................................... 9
5. Use and operation........................................................................................................................................................10
5.1. System operation.............................................................................................................................................. 10
5.2 .Preparation and inspection before use......................................................................................................... 29
5.3. Description of safety precautions during equipment use...........................................................................30
5.4. Operating procedures, methods, precautions and preventive measures .............................................30
5.5 .Electrical schematic diagram.......................................................................................................................... 32
5.6 .Details of main components：........................................................................................................................45
6. Drive parameter setting and troubleshootin.............................................................................................................47
7. Maintenance and maintenance..................................................................................................................................53
8. Transportation and storage........................................................................................................................................ 55
8.1. Precautions for hoisting and transportation..................................................................................................56
8.2. Storage conditions............................................................................................................................................56
9. Schedule........................................................................................................................................................................57
9.1. Random accessories list..................................................................................................................................57
9.2. Recommended spare parts list.......................................................................................................................58
10. After sale......................................................................................................................................................................60
10.1. Product after-sales service guarantee........................................................................................................ 60
10.2. Precautions for maintenance........................................................................................................................61
OperationManualReflexFastFormGX616CNCRebarStirrupBendingMachine

Tips: Thank you for purchasing our products. Please read the Instructions carefully before use.
CHARACTERISTICS:
1.Product description
1.1. Features of this product:
★Integrated automatic feeding mechanism to ensure high dimensional accuracy.
★The external design of the air compressor ensures good heat dissipation and convenient
transportation and installation.
★Split, multi-purpose blade design reduces consumption costs.
★Two-wire bidirectional bending, with more bending shapes and higher efficiency.
★The power of the feeding servo motor is increased to ensure the accuracy when bending
the rebar.
★Intelligent fault identification and alarm system makes maintenance more convenient.
★Pneumatic design of the observation door makes adjustment and maintenance convenient,
safe and fast.
★The design of the pay-off frame with brake can prevent the line of the pay-off frame from
being disorderly caused by the shutdown.
★400 kinds of processing graphics can be input in advance, and it can be used immediately
during processing, which has a high degree of automation.
★Straightening wheels, traction wheels, and meter wheels are made of special steel materials,
which have longer service life and lower operating costs.
★The touch screen operation console is convenient and quick to operate.
★Optional automatic material receiving device, material receiving is more efficient and safe.

1.2. Main purpose and scope of use
The automatic CNC steel bar bending machine REFLEX -FASTFORM -GX616 is mainly used for mass
production of steel bar stirrups , hook bars , slab bars , etc . in infrastructure construction such as
highways, railways, bridges, tunnels, and housing construction
2.Structural features and working principle
2.1. Mechanical structure features and working principle:
Mechanical structure features: This product consists of 1 disc wire rack, 2 pre-feeding mechanism, 3
pre-adjusting mechanism, 4 traction ns. The raw materials used are 6-16 discs and snails.
mechanism, 5 straightening mechanism, 6 shearing mechanism, 7 bending mechanism, 8 return
mechanism, 9 plate ribs It is composed of material rack, 10 consoles, 11 air compressors and other
parts.
The pay-off rack with brake disc can effectively prevent the equipment from starting and
stopping during fast operation, which may cause problems such as disordered feeding of steel bars.
The pre-feeding mechanism can assist the rebar to penetrate the equipment for the first time and
reduce the labor intensity of workers.
The pre-adjustment mechanism pre-adjustment wheel is made of alloy tool steel, which is
resistant to abrasion and impact.
The traction mechanism is equipped with a high-power servo motor to ensure the smooth
operation of the traction. The square-head transition connection is adopted, and the strength is more
than ten times that of the traditional flat key connection. The traction wheel and the straightening
wheel are made of alloy tool steel, which is resistant to wear and impact.
The straightening wheel of the straightening mechanism is made of alloy tool steel, which is
resistant to abrasion and impact.
The shearing mechanism adopts a split thick blade design and is bolted to the blade seat. At the
same time, the thickness reaches 40mm, which is quick to replace and easy to maintain, which
greatly reduces the maintenance cost of the equipment.
The bending mechanism adopts the forming wheel to bend to make the bending steel bar pattern
more standard . At the same time, it adopts double-stroke bending and expansion , which can meet the
production and production of the plate and hook bars of the long hook plate.
The return mechanism adopts double-stroke return expansion and contraction, which can meet
OperationManualReflexFastFormGX616CNCRebarStirrupBendingMachine

the production and production of the plate ribs and hook ribs of the long hook plate.
The heightened design of the slab bar rack and the rack box can meet the production of slab bar
and hook bar of long hook plate. The auxiliary material hook design can realize the non-stop
operation of the finished slab bar hook bar packaging and handling.
The operation table adopts touch screen operation, which is convenient and intelligent.
The air compressor adopts a 7.5KW red five-ring high-power, large-tank air compressor to ensure
a stable and sufficient air source for the equipment.
Working principle: Bundles of coils and snails are placed on the disc wire rack and pass through
the guide wheel. The pre-feeding mechanism sends the steel bars into the host for the first time (the
pre-feeding mechanism is not used during normal work), and the pre-adjusting mechanism removes
the steel After pre-straightening, the traction mechanism is sent to the straightening mechanism to
straighten the steel bars, and the steel bars are sent to the bending part for bending. After bending
and forming, the shearing mechanism cuts the steel bars into shape. When making slab bars and
hook bars, the bending part bends the first hooks of the slab bars and hook bars, and then traction
continues to feed the material to the slab bar rack. When the set length is reached, the shearing
mechanism cuts the bars and passes The return mechanism clamps and provides power for reverse
feeding, and the second head hook is bent into shape by the bending mechanism again, and the plate
rib material rack box is opened to put down the finished plate ribs and hook ribs.

·
2.2. Electrical structural features and working principles
2.2.1 Real shot diagram of electrical control cabinet electrical system structure
layout
described as follows:
"1": indicates the main power switch; "2": indicates the control power switch;
"3": Means the intermediate relay for control. The PLC realizes the control of the solenoid valve of the
equipment by turning on and off the power supply of the intermediate relay coil;
"4": Represents the isolation transformer for control, which provides 220v single-phase power supply for PLC,
switching power supply, and control cabinet cooling fan.
"5": Represents the main contactor of AC power supply. When the key switch of the operating console is
closed, the main contactor coil of the AC power supply will be energized and closed, and all loads and control
power circuit breaker switches will be energized.
"6": indicates the forward rotation AC contactor of the shearing motor; "7": indicates the AC contactor of the
shearing motor brake coil;
"8": indicates the pre-feeding forward rotation AC contactor; "9": indicates the pre-feeding reverse AC
contactor;
"10": Represents the programmable logic controller PLC, the core component of the equipment. It can
communicate with the touch screen/servo driver to realize the size and angle control of the production steel
bars.
"11": Represents the PLC expansion module, which mainly realizes the control of the equipment speed by
sampling the potentiometer.
"12": indicates the control power signal wiring terminal; "13": indicates the traction motor servo driver;
"14": indicates the servo driver of the return motor; "15": indicates the servo driver of the bending motor.
"16": Represents the main power incoming wiring board. "17": Represents the motor wiring board.
"18": Represents the console control circuit wiring board
2.2.2 Working process and principle of equipment and electrical appliances:
Manually feed the steel bars into the pre-feeding rollers and press them by cylinders; click "Pre-feeding motor
OperationManualReflexFastFormGX616CNCRebarStirrupBendingMachine

forward" if safety is confirmed, the steel bars are fed into the upper and lower traction wheels, and click the
"cylinder compression" button. The steel bars are compressed; select the processing required Set the
production quantity, click the "download" button to download the production graphics data to the PLC
controller; set the "manual/automatic" button to the middle position and press it, the bending axis will
automatically return to the original position, select "encoder valid", " Bending limit is valid", "potentiometer is
valid" and the traction and bending speed are set through the potentiometer; select "single action/continuous";
set the "manual/automatic" button to the "automatic" position, press the "start" button, at this time , The
equipment will automatically execute and complete the set production tasks.
3. Technical characteristics
3.1 The main technical parameters of the equipment
Single wire bending diameter 6–16mm
Rebar double wire bending diameter 6–12mm
Processing material Disc round, disc snail
Maximum towing speed 100 m/min
Maximum bending speed 1050 °/sec
Rib straightness error 0.02/1 meter
Total power of equipment 65KW
Average power consumption 10KW/H
Bending direction Two-way
Stirrup length accuracy ±1mm
Rib length accuracy ±5mm
Angle accuracy ±1°
Maximum bending angle ±180°
Longest stirrup side 1000mm
Shortest stirrup side 90mm
The longest length of the rib 9 meters
Working temperature -5~40 ℃
Traction control method Servo
Bend control method Servo
Loopback control method Servo
Total Weight 5.5T

3.2. Overall dimensions and installation dimensions
Equipment dimensions: length, width and height: 14×1.53×2.6m
Installation size 36×5m
Equipment installation and placement plan:
3.3. Main features
It can automatically complete the straightening, sizing, bending and forming and cutting of steel bars.
It can be bent in both directions and two lines, and the processing capacity is very comprehensive. At the
same time, the return mechanism and the material rack can be used to complete the production of hook ribs
and plate ribs, realizing multiple uses in one machine. The equipment uses a numerical control system, and
controls the servo system through a touch screen and PLC. The finished stirrup has high processing
precision, stable and reliable quality, and has a strong graphic storage capacity. It is simple to operate and
convenient to set up, which can save a lot of labor and waste. Improving processing efficiency is an
indispensable part of modern construction buildings, and it is also an intelligent equipment that meets
national standards.
OperationManualReflexFastFormGX616CNCRebarStirrupBendingMachine

4. Installation and debugging
4.1 Equipment installation conditions, installation technical requirements
①A four-core copper-core cable with a long distance between the equipment provided by the user and the
electrical box, with a specification of 3×16+1x10mm² and above, and properly grounded as required;
②The switch specification in the user-supplied electrical box is a 3-phase 4-pole air switch with a rated
current of 150A or more. If a leakage switch is used, the rated current should be more than 150A and the
leakage action current should be more than 150mA. And must be reliably grounded;
③The installation site is 5 meters wide and 36 meters long, and the cement level is on the ground. The main
machine occupies 14×15.3 meters, and the disc wire rack and steel bars occupies 5×25 meters. The site is
required to be sheltered from wind and rain to prevent the precision electronic components of the equipment
from getting wet, which may cause damage to the equipment.
4.2 Installation and debugging methods and matters needing attention
①Use crane or forklift mainframe with a load-bearing capacity of ≥5T to place it in the working position;
②Connect the console and the host well;
③Connect the air compressor to the main engine;
④Assemble the disk and round frame and place it in a reasonable position;
⑤Run the equipment dry, if there is no fault, you can penetrate the steel bar for trial production;
⑥After the test run is normal, fix the disc round frame, main machine, and plate reinforcement frame with
anchor bolts firmly.
4.3 Before trial run, trial run
Before trial operation, check whether the power supply voltage is abnormal, whether it is within three-phase
380V±5%, whether the wire ends of the connecting wires in the electrical box are off, especially the
connection of the PE grounding wire, confirm that there is no abnormality, and then turn on the main power
switch. During the trial run, the traction and bending speed should not be driven too fast to avoid collision.
The test graphics range from simple to complex. When the trial run is correct, the speed can be gradually
increased for normal production

5. Use and operation
5.1 System operation
Note: The operation can only be performed after ensuring that the circuit is normal and the grounding
wire is tight.
There is an obvious grounding point inside the electric control box of the equipment. The PE wire must be
connected to the grounding point when the equipment is installed, but it is never allowed to connect the N (
zero line) to the grounding point! For the first time, it is recommended that you run the main engine dry for 2
hours before entering the steel bar test machine!
(1) First turn on the main power supply;
(2) Install the operating platform, the direction is the same as the front of the machine, the operator faces the
operating platform, and opens the pneumatic door of the automatic guard of the traction wheel.
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OperationManualReflexFastFormGX616CNCRebarStirrupBendingMachine

a. If there is an alarm, press it once reset the button to clear the alarm.
b. Move the manual/automatic knob switch to the left Manual gear, and then move the traction
forward and reverse jog knob to the left or right, and observe whether the direction of the traction wheel
is consistent with the direction of the traction. It is defined here as: to the left is the traction forward
direction, and to the right is the traction backward direction.
c. Move the bending forward and reverse jog knob to the left or right, and observe whether the
direction of the bending arm is consistent with the direction of pulling. This is defined as: when the
operator faces the front of the machine, pulling to the left means that the bending arm rotates clockwise,
and pulling to the right means that the bending arm rotates counterclockwise.
d. The touch screen can also be operated manually, the specific method is as follows:
Click the manual button in the running screen to enter the manual screen, and follow the instructions in the
text.
(5) Automatic simulation operation:
After debugging the traction, bending and jog, confirming the direction is correct, you can enter the automatic
simulation operation.
a. Open the Chinese running
screen:

b.Click the template button in the running screen, and click the graphics to be processed
Take the rectangle as an example: click the button and the following screen will appear:
OperationManualReflexFastFormGX616CNCRebarStirrupBendingMachine

Set the first paragraph, the length of the two sides and the end.
c.Click the
save button to save into the system, and then click
download to
confirm as the current job
Service; finally click to return to the running
screen.
d. Click the button at
the bottom of the
touch screen to open the parameter setting
screen

When you click
once to switch to
the state, you can simulate
the stirrup feeding operation.
Note: When the hoop is bent normally, it must be switched to the encoder effective (closed-loop
feeding) state!
e. Move the manual/automatic knob switch to the middle, return to the reference gear, press the start
button once, and the bending arm will return to the original position at 12 o'clock.
Move the manual/auto knob switch to the right automatic gear, the single-step/continuous knob to the
left single-step gear, press the start button once, and the system will automatically perform a hoop
bending simulation operation.
f. Enter the value in the box of planned output on the touch screen,Set the number of bending steel bars
to one or two
g. Move the single step/continuous knob to the continuous gear on the right and press the start
button once. At this time, the system will automatically execute the planned number of hoop bending
simulation operations until the output is completed.
i. Clear the current output:
Click to complete the output ，Or clik Clear the already
produced quantity.
j. When there is an emergency or wrong action, the emergency stop button must be pressed in time.
k. Remove the error according to the alarm prompt on the display screen, and press the reset button to
restore the ready-to-work state.
OperationManualReflexFastFormGX616CNCRebarStirrupBendingMachine

l. When pressing the emergency stop button or switching from another state to the automatic state, it needs
to return to the reference (the bending arm returns to the origin).
Note: When a failure occurs during automatic operation and the structure cannot be returned to the initial
position of work, press the emergency stop and reset it in the manual gear to return to the reference.
(6) Parameter setting
1) When performing a new production task, mechanical adjustment is required, which may produce several
unqualified samples. Please make a single-step adjustment when debugging.
2) Please select the appropriate mold after changing the diameter of the steel bar. There are two standard
molds for this model, the specific parameters are as follows:
Click the icon，
3) The mold parameters have been preset before leaving the factory, please do not adjust
for hooks，for stirrups
Please confirm whether the mold is correct when making steel bars!
Note: The steel bars of the same batch and the same diameter cannot be changed at will! Otherwise,
the angle will be inaccurate!
4) The angle adjustment corresponds to the diameter of the steel bar
When working, the speed will have some influence on the length and angle. Please fine-tune the length and

angle of the machine after the speed is fixed.
5) The internal programs and key parameters of the servo drive, touch screen and PLC have been set before
leaving the factory, and we need to designate professional and technical personnel to modify the operation,
and other personnel are not allowed to modify it privately!
6) Speed setting
7) Note: When processing ￠12 round steel or rebar, the processing speed should be limited, otherwise the
machine will be seriously damaged if the speed is too fast. When the size of the bending stirrup (side length
or diagonal side length) is greater than 400 mm, the bending speed should be slowed down accordingly.
These have been set in the program, but the customer should adjust it according to the actual situation.
8) Tail length compensation, demold length setting
5.1.2 Operation instructions of touch screen system
Language selection screen: (standard version in six languages)
The screen shown in the figure below is the main operating screen of the hoop bending machine touch
screen system:
OperationManualReflexFastFormGX616CNCRebarStirrupBendingMachine

illustrate:
First, turn the manual/automatic knob of the console to the left manual position.
●The feedback pulse value in the screen shows the basic parameters that the servo motor must have for
operation;
● The same function as the traction knob switch of the console;
● It has the same function as the operation desk bending knob switch, the middle is the
function of returning to the origin;
●
The above buttons respectively operate the extension and retraction of the bending arm, the central axis
mold, the return device, the material receiving rack, and the blanking rack.
B) Overall compensation function
When pressing the touch screen to run the screen

illustrate:
Compensation parameters: They are angle overall compensation and circular arc overall compensation,
which are set by the corresponding compensation buttons. In the actual debugging, you should first run in a
single step, and modify the parameters according to the actual bending effect. If the bending angle is too
large, decrease the compensation value (it can be a negative number), and vice versa. If you want to log out,
please click on the upper right of the input box 。
C) Basic graphic template
OperationManualReflexFastFormGX616CNCRebarStirrupBendingMachine

When you press the template button
on the run screen, the following screen will appear:
Note: The above 11 templates are shortcuts for curved graphics. When you touch the required template, the
corresponding ones will pop up.
The setting graphics parameter screen, for example, when the button
is touched, the following
screen will appear:

Note: Under normal circumstances, the tapping (first section) and shrinking (tail section) are about 10 times
the diameter of the steel bar; and not less than 8 times the length, otherwise it will cause equipment failure.
The user only needs to enter the two opposite sides A and B of the rectangle. The length is sufficient.
D)Electrical and mechanical basic parameter settings
When you press the button at the top of the running screen, the following screen will appear:
OperationManualReflexFastFormGX616CNCRebarStirrupBendingMachine