SPECIFICATION FOR QUOTATION Side Semi-Auto Punching & Riveting Machine … · 2016-02-06 · 2....

NOTE: Side-3 and Side-2 Semi-Auto Machine share the same specification sheet. Quantity req'd will

be specified at the time of quotation and purchase order. Quantity will be separate: 1 set Side-3

Semi-Auto Machines (1 set = 4 machines) OR 1 set Side-2 Semi-Auto Machines (1 set = 4 machines)

1. Overview

2. Detail Machine Specifications

Fabrication New Remodel

Type ●

Candidates of Quotation

Riko Tantra Suyong Yoon

Manufacturing Engineering Distribute to

Dept. Head of Dept. Remarks Procurement Department

Production Side Production

Maintenance

Maintenance Safety

Candidates

Safety

No. Draft/Revise Date Description Check by

1 Jan. 26, 2016 Draft Riko Tantra

2 Jan. 30, 2016 Added Side-2 Semi-Auto (Same Spec Sheet) Riko Tantra

3 Feb. 06, 2016 Added detail on Motorized Control Riko Tantra

4

Rev.

● Side-2 Semi-Auto Punching & Riveting Machine (1 Top, 1 Bottom)

(HT Side-2 Semi-Auto Stage)

Project REF No. MFG2016-20

1 / 12

SPECIFICATION FOR QUOTATION

● Side-3 Semi-Auto Punching & Riveting Machine (1 Top, 1 Bottom)

(HT Side-3 Semi-Auto Stage)

Approval

Prepared by

Side Semi-Auto Punching & Riveting Machine (1 Top, 1 Bottom):

Confirmed

Date

Responsible Dept.

Related

Dept.

Checked by Checked by

Project REF No. MFG2016-24

OR

1. Overview

■ Overview 2 / 12

Article Detail

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Remarks

C/TIME OP Condition

Prod Capa'

Main Power Control Power

Main Air Cooling Water

Soundproof Room Fueling/Lubri

Net/Fence M/C Door

Noise Indoor Temp

Record at Manual whether waste arises at the time of installation, mass production

including type of waste and handling/disposal method. Train to Maintenance member.

1.Use high efficiency motors.

2.If it needed, apply energy saving function at driving unit to stop automatically after

normal cycle when the operation stops by Breaktime or mealtime.

- Grasp the regulation of firefighting, Safety, Environment, and observe it during

machine design, fabrication, installation, tryout and mass production.

- Refer to Common Standards

Standard International Standard or Standard of applicable Country or Region

Inspection ■ Self inspection and tryout by maker

HT Provide Forklift. Support main power connection. Participate in Tryout

Maker

May 2016 (Installation)

Local Maker: DAP / USA Maker: FOB / Korean Maker: CIF Long Beach (L/T: ARO - Arrival at Plant)

MP React Mass Production Reaction: until 2 weeks after final tryout (Refer to Common Standards)

Warranty until 1 year after Final Termination Inspection Approval (Refer to Common Standards)

- Passed Final Inspection Check Points related Specifications.

- Handovered all needed drawings, manuals, spare parts and training.

- Refer to Common Standards for more detail

Scope 1 Mechanic and 1 Electic required

Scope 1) Condition: Provide as option 3% of Overall Equipment Amount (Include in quote)

Arrival Parts 2) PARTS LIST & Unit Price : Provide when submit quotation

Cut 3/1000 of Contract Amount every 1 day delay, upto 10% when the fault issued by provider.

Based on 1 month after MP: more than 95% (Based on 2 months after MP: more than 98% )

Relevant models of project will be shared

1) To be common use of model change part. If not possible, apply Quick Change Type.

2) Limit Time in case of manual model change: below 30 minutes.

3) Production Type : LOT

4) Different model reaction : issue ALARM & M/C STOP

5) Special Note: Apply the Model Selection Switch at MAIN OPERATING BOX

6) Refer to HT Specification for Common Specification.

80~90 psi (5.6~6.3 ㎏/㎠) N/A

AccessoriesN/A refer to detail

Safety Barrier Safe Circuit

Regulation

SpecChk

Ba

sic

Co

nd

itio

n

M/C Capa'M/C = 15 min/cycle, Line = 33 min/set 6,200 Hr/Year

16 unit / shift

UtilityAC 460V(±10%) × 3Φ × 60 Hz AC110V and DC24V

Delivery Conpensation

Plant

Environm't

Required Delivery

Below 85DB (Refer to Common Standards) -10℃ ~ + 45℃

Regulation and

standard

Fabrication

Inspection and

Installation

□ visit incharge of HT to Maker

InstallationSupervise and perform the installation and tryout

Model Reaction

Termination

Condition

M/C Operation Rate

Application Model

Industrial

Waste

Energy

M/C Delivery Terms

Warranty, After

Service

MP React

Spare Parts


■ Side Semi-Auto Top and Bottom Punching & Riveting Machines (1/10) 3 / 12

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1 Equip' Name Side Semi-Auto Top and Bottom Rail Punching and Riveting Machines

2 Quantity 1 set Semi-Auto Punching M/C's (1 Top Rail M/C, 1 Bottom Rail M/C -- See Composition Below)

1 set Semi-Auto Riveting M/C's (1 Top Rail M/C, 1 Bottom Rail M/C -- See Composition Below)

3 Applying Location Side-3 Semi-Auto Stage (for MFG2016-24) or Side-2 Semi-Auto Stage (for MFG2016-20)

4 Use of Equipment The system are for producing Dry Van Trailer, Domestic Container, Reefer Trailer, and Plate

Trailer Sidewall Assembly by Punching & Riveting Top and Bottom Rails to the Side Ass'y at Post

locations. The holes from the Semi-Auto Punching Machines are then inserted with rivets that

are then squeezed by the Semi-Auto Riveting Machines.

The Punching & Riveting Molds are easily interchangeable for different production models.

5 Product Type - Side Assembly of Dry Van, Reefer, Dom-Con, Plate Trailer.

- Length: 28', 33', 35', 38', 40', 45', 48', 53'; Side Post Pitch: 12", 16", 24"

6 Material (Detail Side Ass'y material components will be described in more detail in this spec sheet)

7 Work Scope(Vendor) - Design(CAD), Fabrication, Assembly, Fabrication Inspection&Test, Manual & Catalog

- Packing, Loading, Shipping, Unloading, Unpacking, Carrying into Site

- Installation, Setting, Try-out

- Required Utility(Electric,air,etc) Drawing, Machine Foundation Drawing (If required)

8 Work Scope(HT) - Drawing/Specification Approval, Building Remodeling, Machinery Foundation

- Main Utility Connection, Existing Equipment Relocation

- Try-out Supports, Forklifts for installation, Provide Try-out Materials/Products

- Final Termination Inspection

9 Layout & Process See below as Reference

* Reference image for Concept understanding

SpecChk

Reference (Layout / Drawing / Picture)

Existing Steel Rails to

be Re-Used for the new

machine (REF only)

New Machines Wheels must fit the rails dimensions (inside-inside rails dimensions)

Semi-Auto M/C's (BOT):

1 set Punch M/C, 1 set Rivet M/C

Semi-Auto BOT MC (REF)

Semi-Auto Punch

M/C (BOT)

1 set

Semi-Auto Punch

M/C (TOP)

1 set

Semi-Auto Rivet

M/C (BOT)

1 set

Semi-Auto Rivet

M/C (TOP)

1 set

Semi-Auto M/C's (TOP):

1 set Punch M/C, 1 set Rivet M/C

Semi-Auto TOP MC (REF)

Product Movement

Machine Movement

NOTE: Layout shown is based on Side-2 Semi-Auto

revised inside rail-rail dimensions to make universal, and

for worst case condition (tight clearance to column)Dimensions are FOR REFERENCE ONLY for quotation. Final dimensions to be confirmed with HT.

Building

Column



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10 Composition 1. Semi-Auto Side Ass'y Top and Bottom Rail Punching Machine - 1set (1 set Top, 1 set Bot)

1.1. Cart System (Optional: Motorized Cart System) - 1 set (1 set Top, 1 set Bot)

1.2. Side Semi-Auto Punching Unit - 1 set (1 set Top, 1 set Bot)

1.3. Hydraulic and Pneumatic System (Optional: Air Compressor) - 1 set (1 set Top, 1 set Bot)

1.4. Molds - 1 lot (1 set Top, 1 set Bot)

1.5. Control Panel, Electrical System & Electrical Power Bars - 1set (1 set Top, 1 set Bot)


SpecChk

1.B. Semi-Auto Punch M/C (BOT) 1.T. Semi-Auto Punch M/C (TOP)

250mm 450mm

1.1 1.1

1.2B

FRONT VIEW (REF FOR

BOT & TOP M/C)

1.2T1.3

1.4B 1.4T

1.5 1.5

3*

3* Side Ass'y Alignment Jig is attached to Side Conveyor to align Side Ass'y to certain distance from side edge of conveyor

prior to the Side Semi-Auto machine operation

1.B. Semi-Auto Punch M/C (BOT)

1.T. Semi-Auto Punch M/C (TOP)

Product Movement

Machine

Movement

Dimensions are FOR REFERENCE ONLY for quotation. Final dimensions to be confirmed with HT.



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10 Composition 2. Semi-Auto Side Ass'y Top and Bottom Rail Riveting Machine - 1set (1 set Top, 1 set Bot)

(Cont'd) 2.1. Cart System (Optional: Motorized Cart System) - 1 set (1 set Top, 1 set Bot)

2.2. Side Semi-Auto Rivetting Unit - 1 set (1 set Top, 1 set Bot)

2.3. Hydraulic and Pneumatic System (Optional: Air Compressor) - 1 set (1 set Top, 1 set Bot)

2.4. Molds - 1 lot (1 set Top, 1 set Bot)

2.5. Control Panel, Electrical System & Electrical Power Bars - 1set (1 set Top, 1 set Bot)

3. Alignment Jig (Optional) - 1set (1 set Top, 1 set Bot)


SpecChk

2.B. Semi-Auto Rivet M/C (BOT) 2.T. Semi-Auto Rivet M/C (TOP)

2.1 2.1

2.2B

FRONT VIEW (REF FOR

BOT & TOP M/C)

2.2T2.3

2.4B 2.4T

2.52.5

3*

3* Side Ass'y Alignment Jig is attached to Side Conveyor to align Side Ass'y to certain distance from side edge of conveyor

prior to the Side Semi-Auto machine operation

2.B. Semi-Auto Rivet M/C (BOT)

2.T. Semi-Auto Rivet M/C (TOP)

Product Movement

Machine

Movement




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11 Work Process 1. Side Ass'y at station with Side Top & Bottom Rail Tacked, is aligned to conveyor with

the Alignment Jig

2. Operator push the button to remove the brake and push* to bring semi-auto punch machine to

the 1st post, align with laser pointer and punch the holes at post locations thru Side Panel,

Side Post, Side Bottom/Top Rail Extrusion. Optional: motorized system in lieu of pushing.

3. Operator move the machine to the next post location, punch, etc. until finish the full length

4. Another Operator insert rivets manually in the punched holes on Top and Bottom Rails

5. Another Operator push the button to remove the brake and push to bring semi-auto rivet m/c

to the 1st post, align with laser pointer and squeeze the rivets at post locations thru Side

Panel, Post, Side Bottom/Top Rail Extrusion. Optional: motorized system in lieu of pushing.

* For Motorized Option: Select Direction (FWD, NEUTRAL, REV) , Select the Movement

Distance knob (12", 16", 24") , Trigger the handle (handle must be ergonomics, similar to the

one in an electric pallet jack system , as reference) to move, Release the handle at/close to

post location, Jog back/forth for fine adjustment at slow speed, then Punch or Rivet operation.

Motor to be with brake when not moved. Clutch release function in case motor is damaged

in order to allow manual push. It must also have speed control adjustment at the control.

Basic 'Homing' function with alarm . Electric Safety Bumpers at front and rear for E-Stop.

12 Specification 1. & 2. Semi-Auto Side Ass'y Top and Bottom Rail Punching and Riveting Machine

- 1 set Semi-Auto Top and 1 set Semi-Auto Bottom Rail Punching M/C running independently

- 1 set Semi-Auto Top and 1 set Semi-Auto Bottom Rail Riveting M/C running independently

- ALL machines to use existing standard rails in the line.

- ALL machines to use new sets of power bars to ensure best machine performance

1.1. & 2.1. Cart System (1 set - 1 set Top Punch, 1 set Bot Punch, 1 set Top Rivet,

1 set Bot Rivet Machines)

- Cart System to run on existing rails cross-section view and center-to-center shown above

- Basic machine: Pneumatic brake (released with a button), carts are pushed manually.

- Optional: Motorized system (switch for direction FWD/REV, grabhandle control w/ trigger

to run the machine -- stopped when released for safety, E-Stop, speed control adjustment

knob (speed range: 0 ~ up to 18 m/min, jog function at handle control), see above for detail

Basic homing system option for motorized system with alarm

1.2. Semi-Auto Punching Unit (1 set - 1 set Top and 1 set Bottom Machine)

& 2.2. Semi-Auto Rivetting Unit (1 set - 1 set Top and 1 set Bottom Machine)

- Punching Yoke & Riveting Yoke are slideable IN/OUT with pneumatic cylinder

(BOT: 250mm, TOP: 450mm stroke)

- Yoke to have manual UP/DOWN adjustment with hand crank-wheel

- Pneumatic Backup Cylinder on bottom to bring Yoke up and hold material during process

- Include Hydraulic Cylinder on top for punching/ riveting operation

SpecChk

3*

Motorized Handle

Design Reference, but

must be heavy duty

(aluminum/ steel)



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12 Specification (Cont'd) - 2 sets of laser pointer (1 for double rows, 1 for single row), installed securely, with

adjustment in Y-Direction only and not in X-Direction, to avoid any movement in operation

Example: For Std Dry V/T model Bottom M/C and Reefer Bottom M/C mold, will use laser#1

and laser #2 respectively. (see diagram below)

Punching/ Rivetting Operation

Sequence:

SpecChk

Laser Laser

Punching/ Rivetting

Hyd. Cylinder

Punching / Rivetting

Hyd. CylinderHand Crank Wheel

Backup

Hyd.

Cylinder

FWD Switch ON

Yoke UP

Pusher FWD

Punch/Rivet FWD

Punch/Rivet REV

Pusher REV

Yoke DOWN

Air Blow

Press Switch

Laser #1

ON

Laser #2

OFF

Laser #1

OFF

Laser #2

ON

Y-axisY-axis




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12 Specification (Cont'd) 1.3. Hydraulic and Pneumatic System for Punch M/C (1 set = 1 set Top and 1 set Bot M/C)

& 2.3. Hydraulic and Pneumatic System for Rivet M/C (1 set = 1 set Top and 1 set Bot M/C)

- Hydraulic system for punching/ rivetting cylinder

- Air cylinders to push Yoke UP to hold Side Ass'y during punching/ rivetting

- Hydraulic pump: working condition (during process) must be only at 60% maximum pump

capacity to ensure durable operation (NOTE: Larger than current hyd. system that require

regular maintenance of hydraulic pump system)

- Hydraulic system includes: Cooling System and return line filter

- Pneumatic system includes: an air compressor with enough capacity for entire pneumatic

requirement, to avoid long air lines connected to machine.

1.4. Punching Molds (1 lot, see detail)

- Molds to be easily changed for model change (Bolt-On)

- Mold Patterns (1 set each): 6 Total TOP Molds, 3 Total BOT Molds (see below list)

- Some models have 'Optional-1' & 'Optional-2' by electric-pneumatic solenoid selector

above the punch pins of particular punches. Must be safe operation.

- To include spare punches = 20 pcs/ machine

- To include spare die bushings = 20 pcs/ machine

- To apply quick change for the punch & die bushings

- Punches and dies are made of Tool Steel (D2) material for proper punch & die application

SpecChk

Punch Mold BOT

(REF ONLY)

Punching / Rivetting

Yoke System

Pneumatic & Hydraulic



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12 Specification (Cont'd) 2.4. Rivetting Molds (1 lot, see detail)

- Molds to be easily changed for model change (Bolt-On)

- Mold Patterns (1 set each): 4 Total TOP Molds, 2 Total BOT Molds (see below list)

- Some models have 'Optional-1' & 'Optional-2' by electric-pneumatic solenoid selector

above the punch pins of particular punches. Must be safe operation.

- To include spare Top Die = 2 each type

- To include spare Bottom Die = 2 each type

- To apply quick change for the Top and Bottom Die

- Top and Bottom die are made of Tool Steel (D2) material for proper squeezing application

SpecChk

TOP BOTTOMTYPE

MANUAL PUNCHING

V/T Dry

V/T Reef

Dom-Con

Plate

Trailer

Optional-1

Optional-2

Optional-1

Optional-2

Punch: Ø 6.95

Die: Ø 7.8

Punch: Ø 6.95

Die: Ø 7.8

Punch: Ø 6.95

Die: Ø 7.8

Punch: Ø 6.95

Die: Ø 7.8

Punch: Ø 6.95

Die: Ø 7.8

Punch: Ø 6.95

Die: Ø 7.8

Punch: Ø 6.95

Die: Ø 7.8

Punch: Ø 6.95

Die: Ø 7.8

SAME SAME

TOP Punch MOLD (Std Dry V/T shown)

BOT Punch MOLD (Std Dry V/T shown)

Rivet Mold BOT

(REF ONLY)



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SpecChk

TOP Riveting MOLD (Std Dry V/T shown) BOT Riveting MOLD (Std Dry V/T shown)

TOP BOTTOM

V/T Reef

V/T Dry

MANUAL PUNCHING & RIVETINGTYPE

Optional-1

Optional-2

Optional-1

Optional-2



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12 Specification (Cont'd)

Side Bottom & Top Rail Extrusion: A6061S-T6 Aluminum Extrusion

Side Post: Grade "D" Galvanized Steel; Side Panel: 1.22mm thick A3004-H291 Pre-Painted Aluminum

SpecChk

Sample Side Ass'y Manual Punching & Rivetting Pattern (STD Dry V/T shown)

STD Dry V/T Bottom Rail:

STD Dry V/T Top Rail:

STD Dry V/TSide Panel Top Rail

Bottom Rail

Side Post

Type-1 Type-2

Bot Rail Top Rail

Type-3



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12 Specification (Cont'd) 1.5. Control Panel (1 set = 1 set Top and 1 set Bot Punch M/C)

& 2.5. Control Panel (1 set = 1 set Top and 1 set Bot Rivet M/C)

- Power ON/OFF: to turn ON/Off equipment and Hydraulic motor

- FWD: Yoke Up, Pusher Forward, Punch Forward

- FWD STOP: Stop Punching Machine

- POST Check ON/OFF: Turn the post checking ON/OFF

- E-STOP: Yoke Down, Pusher Retract, Punch Retract

SEE PAGE 6/12 FOR DETAIL IN MOTORIZED CONTROL OPTION (Handle control, jog, etc)

3. Alignment Jig (1 set)

- Attached to Side Conveyor to easily align side ass'y to side conveyor with pneumatic system

- REF ONLY: Currently worker use a measurement stick to check distance between bottom

rail to conveyor at both front & rear and adjust by pulling/pushing manually. (need improve)

SpecChk

REFERENCE PICTURES

Punch Mold (REF)

Rivet Mold (REF) Rivet Mold (REF)

Motorized Handle

Design Reference, but

must be heavy duty

(aluminum/ steel)

SPECIFICATION FOR QUOTATION Side Semi-Auto Punching & Riveting Machine … · 2016-02-06 · 2....

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