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2026-08-25
Applicable Models: Forklift palletizer for small and medium diameter welded pipes (Φ20–168mm, 6m fixed length), hydraulic + servo drive, PLC touch screen control
Operating Conditions: 380V three-phase power, air supply 0.4–0.6MPa
Safety Rules: Unauthorized personnel are prohibited from operating the machine; entering the forklift extension/lifting area is strictly prohibited during machine operation; overloading is strictly prohibited.
I. Three Operating Modes
1. Manual Mode: Equipment inspection, troubleshooting, single-mechanism inching debugging.
2. Semi-automatic Mode: Single-pile single-cycle, used for changing specifications and testing, and calibrating the stack type.
3. Fully Automatic Mode: Used for continuous palletizing during normal production.
II. Pre-Start Inspection (Mandatory every shift)
1. Check the forklift, material feeding mechanism, and bracket for deformation, jamming, and looseness.
2. Hydraulic station oil level is normal and there is no leakage; air source pressure is stable at 0.4–0.6 MPa, and accumulated water in the filter is drained.
3. Clean iron filings from the photoelectric sensor and check that the emergency stop and safety protection devices are intact.
4. Confirm that the equipment area is free of people and debris.
III. Standard Start-up Procedure
1. Turn on the main power supply. The system will perform a power-on self-test and clear alarms.
2. Turn on all emergency stops and click "Fault Reset".
3. In manual mode, perform a full machine zeroing operation (fork arms and stackers all return to their positions).
4. Perform a no-load jog test run to confirm smooth operation without abnormalities before commencing production.
IV. Changing Specification Parameter Settings
1. Use the touchscreen to retrieve the corresponding recipe and input: pipe diameter, number of pipes per layer, and total number of layers.
2. Fine-tune the lifting height of the forklift and the lowering height of the stacker.
3. Perform a semi-automatic test run of 1-2 layers first to confirm that the pipes are neatly arranged and there is no pipe misalignment before switching to fully automatic.
4. Do not modify the hydraulic pressure or system's underlying parameters without authorization.
V. Fully Automatic Production Operation
1. Switch to fully automatic mode and press start after confirming readiness.
Automatic process: Roller conveyor feeding → Material distribution → Forklift receiving → Shifting and stacking → Automatic stacker lowering → Layer-by-layer stacking → Full stack audible and visual alarm.
2. Production inspection: No abnormal noise, no oil leaks, steel pipes are neatly arranged, and counting is accurate.
3. During equipment operation, it is strictly forbidden to put hands or probes into the moving area of the equipment.
VI. Shutdown Operations
Temporary Shutdown (Shift Change): After completing the current layer/stacking, press the stop button. The equipment will return to its original position; the main power supply will not be interrupted.
After-Shift Shutdown: Return the equipment to zero → Turn off the air supply → Disconnect the main power supply → Clean the equipment of metal filings and debris.
Directly cutting off the power to stop the machine during production is prohibited.
VII. Emergency Shutdown
In case of personnel danger, pipe jamming, abnormal noise, oil leakage, or other emergencies, immediately press the emergency stop button.
Reset and restart only after troubleshooting is completed and on-site safety is confirmed.
VIII. Common Simple Fault Handling
Emergency Stop Alarm: Reset all emergency stop buttons to re-reset the fault.
Material Dispensing/Retrieving Failure: Clean the sensor of accumulated dust, remove any pipe jamming, and check for misalignment of incoming materials.
Hydraulic Overload: Check for overload and fork arm jamming; forced operation is prohibited.
Origin point loss: Manually reset to zero. For frequent loss, contact the manufacturer for calibration.
IX. Safety Prohibitions
1. Overloading and production exceeding specifications are strictly prohibited.
2. Entering the equipment's moving area is prohibited during operation.
3. Power must be disconnected and tags displayed before maintenance and clearing stuck materials.
4. Only electricians and technicians are allowed to modify system parameters.
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