HLY-OP-01: Suspension Roller Machine Console Dual-Speed & Auto-Feeding SOP

1. Pre-Shift 5-Minute Safety Checklist

Verify hydraulic tank oil level is at 2/3 of sight glass and temperature is between 20°C and 50°C.

Check main reducer oil level and confirm automatic grease lubricators on roller bearings are active.

Hoist mold onto roller shaft; lock hydraulic tailgate; verify mechanical locking pin drops and safety green light illuminates.

2. 4-Stage Feeding & Speed Calibration Sequence

* Stage 1 (Bedding Layer, 400–600 rpm): Run motor at low speed; advance feed conveyor to spread mix across barrel to 1/2 wall thickness, securing the rebar cage.
* Stage 2 (Joint Reinforcement, 500–700 rpm): Dwell conveyor at spigot and bell ends for 15–20s each to densify joint profiles.
* Stage 3 (Full Pass Smoothing, 600–750 rpm): Feed continuously until concrete sits 3–5 mm proud of end rings.
* Stage 4 (Net Compaction Finish, 900–1300 rpm): Retract feeder; ramp VFD to compaction speed. Strictly observe duration limits:
- DN300–DN600: 3.0 – 4.0 min;
- DN800–DN1200: 4.5 – 6.0 min;
- DN1350–DN2000: 6.0 – 8.0 min.

3. Controlled Stop & De-docking

Never engage emergency brake during routine stop! Decelerate smoothly via VFD ramp (20–30 seconds).

Retract tailgate lock, open hinged tailgate, and hoist the green pipe assembly to steam curing pit.