Case Study: Application of Q91-630 Gantry Shearing Machine with Door Cover for a Client in India

1. Market Background: Growing Need for Efficient Metal Processing in India

India's manufacturing sector has experienced rapid growth over the past decade, particularly in industries such as construction, automotive, and metal recycling. As the demand for raw materials such as steel and aluminum increases, so does the need for efficient, high-performance machinery capable of processing scrap metal into usable forms.

One of the key challenges faced by many Indian recycling plants and manufacturing facilities is the efficient processing of large volumes of scrap metal, especially in harsh working environments. This often involves cutting large metal pieces into smaller, more manageable sections for further use or recycling.

The Q91-630 Gantry Shearing Machine is designed to meet the increasing demand for high-capacity, efficient metal shearing machines in such industries, capable of processing a variety of materials, including round steel, square steel, and steel plates, with high precision.

2. Client's Pain Points: Overcoming Limitations with Existing Equipment

Our client, an industrial plant in India specializing in metal processing and scrap recycling, faced several operational challenges with their existing equipment:

• Inadequate Cutting Capacity:
  The plant's existing shearing machine could not handle the increasing volume of scrap metal. The lack of cutting power and precision was leading to reduced throughput and an increase in the time required to process materials.

• Inconsistent Cutting Quality:
  The existing equipment could not consistently shear large scrap metal sections into smaller pieces, resulting in inconsistency in product quality. This was particularly problematic when processing materials for use in downstream applications, where precision cutting is crucial.

• Maintenance and Downtime Issues:
  The older machine had frequent maintenance issues and was causing high levels of downtime, disrupting production and affecting the overall efficiency of the plant.

The client needed a reliable, high-performance shearing machine capable of cutting a wide range of metal materials quickly and consistently while minimizing maintenance downtime.

3. Solution: Q91-630 Gantry Shearing Machine with Door Cover

After a detailed analysis of the client's operational needs and existing equipment, we recommended the Q91-630 Gantry Shearing Machine with door cover cylinders to address their challenges. This machine is equipped with advanced hydraulic systems and a robust cutting mechanism designed for high-volume metal processing.

Key Features of the Q91-630 Shearing Machine:

1. Powerful Hydraulic System:

   • The machine is equipped with a YG400/280 shear cylinder, capable of delivering 3150 kN of thrust, ensuring high cutting power to shear large metal pieces with ease. With a stroke length of 950 mm and two cylinders, the Q91-630 is designed for high-throughput, high-pressure cutting, ensuring reliable performance even under heavy loads.

2. High-Precision Cutting and Versatility:

   • The machine features a shear blade length of 1600 mm, with a minimum shear opening of 570 mm and a cutting angle of 10.5 degrees. These specifications allow the machine to cut a variety of scrap metal sizes, including round steel (φ140mm), square steel (110×110mm), and steel plates (70×500mm), with high precision.

3. Optimized for Large-Scale Operations:

   • With a pressing length of 530 mm and a maximum opening of 1000 mm, the Q91-630 can handle large metal pieces and bulky scrap, making it ideal for plants that deal with high volumes of material. This flexibility allows the machine to adapt to different cutting tasks with ease.

4. Efficient Hydraulic System and Cooling:

   • The machine is powered by a hydraulic pump model A4V-250, operating at a nominal pressure of 31.5 MPa, ensuring smooth and efficient operation. The inclusion of an IRG-65-125A cooling circulating pump with a motor power of 3 kW ensures optimal hydraulic system performance even during extended operation. Additionally, an oil cooler (model 80000) with a cooling capacity of 80,000 KCAL/HOUR ensures that the hydraulic fluid stays within optimal temperature ranges, preventing overheating and ensuring long-term reliability.

5. Optimized Power and Energy Efficiency:

   • With a total motor power rating of 132.5 kW and three units of 45 kW motors, the Q91-630 provides ample power for high-speed cutting. The machine's energy-efficient design ensures optimal performance while minimizing power consumption during idle and non-load periods.

6. User-Friendly Operation and Maintenance:

   • The Q91-630 is designed with ease of use and maintenance in mind. It includes an intuitive control system that allows operators to quickly adjust settings for different material types and cutting tasks. The robust construction ensures minimal maintenance requirements, reducing downtime and increasing overall plant efficiency.

4. Client Feedback: Increased Efficiency and Consistent Quality

After the installation and commissioning of the Q91-630 Gantry Shearing Machine at the client’s facility in India, the client reported significant improvements in their operations:

• Enhanced Production Efficiency:
  The Q91-630 machine was able to handle the increasing volume of scrap metal, significantly increasing the plant's cutting capacity. The machine's high cutting speed (2-3 cuts per minute under empty load) allowed the plant to process scrap metal more quickly, reducing bottlenecks in the production line.

• Consistent and High-Quality Cutting:
  The consistent cutting quality of the Q91-630, with its precise shearing ability, allowed the client to produce uniform, high-quality metal pieces. This improved product quality was appreciated by downstream customers who required consistent sizes for further processing or recycling.

• Reduced Maintenance and Downtime:
  The Q91-630’s robust construction and efficient hydraulic system reduced maintenance requirements and downtime, allowing the plant to operate more smoothly and maintain high levels of productivity. The cooling system and energy-efficient hydraulic pump played a key role in ensuring reliable operation over long shifts.

• Improved Safety and Operational Conditions:
  The door cover cylinders of the Q91-630 provided added safety during operation, protecting workers from exposure to moving parts and reducing the risk of accidents. The enhanced design also contributed to improved overall safety and operational conditions at the plant.

The client’s operations have significantly improved, and they have expressed satisfaction with the machine's performance, stating:

“Since installing the Q91-630, we have seen a dramatic increase in our cutting capacity and product quality. The machine’s efficiency and reliability have far exceeded our expectations, and we no longer face the downtime issues we had with the previous equipment.”

5. Conclusion: The Q91-630 Gantry Shearing Machine - A Game-Changer for Metal Processing

The Q91-630 Gantry Shearing Machine has proven to be a perfect solution for the client's needs, offering high performance, reliability, and efficiency in cutting a variety of scrap metal materials. With its powerful hydraulic system, advanced features, and energy-efficient design, the Q91-630 has enabled the client to significantly improve their productivity while maintaining consistent cutting quality.

This case study highlights the importance of tailoring machinery to meet specific client requirements, ensuring optimal performance in demanding industrial environments. Jiangyin Huake Machinery Co., Ltd. continues to provide cutting-edge solutions that meet the evolving needs of the global metal processing industry, enhancing efficiency, safety, and profitability for clients worldwide.