Flow chart

Manual decoiler--Guiding--Leveler--Hydraulic pre cut--Roll forming machine--Flying hydraulic cut--Platform--Seaming machine--Out table

Main Techinical Parameters

1. Line speed: 0-4 m/min, adjustable
2. Profiles: Multiple sizes-same height of 50mm, and different width of 80, 100, 120mm
3. Material thickness:1.5-2mm
4. Suitable material:Hot rolled steel, cold rolled steel, galvanized steel
5. Roll forming machine: Cast-iron structure and chain driving system.
6. Of forming station: 18
7. Cutting system: Hydraulic cutting, roll former doesn’t stop when cutting.
8. Changing size: Automatically.
9. PLC cabinet: Siemens system.

Manual Decoiler

The manual decoiler comes equipped with a braking system designed to adjust the tension of the unwinding roll and control the smoothness of the unwinding process. For steel coils exceeding a thickness of 1.5mm, the risk of sudden recoil during uncoiling is minimized by a press arm securing the steel coil. Additionally, steel protection leaves are installed to prevent coil slippage during the uncoiling phase. This thoughtful design ensures not only high cost-effectiveness but also enhances safety.

In this scenario, a manual decoiler without its own power source is employed. For more substantial production speed requirements, we offer an optional hydraulic decoiler powered by a hydraulic station.

Guiding

Guiding rollers play a crucial role in maintaining alignment between the steel coil and the machine, preventing distortion of the box beam. They also contribute to the forming process by preventing rebound deformation of the steel coil. The straightness of the box beam significantly impacts product quality and the load-bearing performance of the entire shelf. Guiding rollers are strategically positioned along the entire forming line, ensuring precise positioning. Measurements of each guiding roller to the edge are meticulously recorded in the manual, facilitating easy adjustments based on this data even if slight displacements occur during transportation or production.

Leveler

Subsequent to this stage, the steel coil undergoes the leveling process. The leveling machine effectively removes the curvature of the steel coil, enhancing its flatness and parallelism to elevate the overall quality of the final product-box beam. The leveling machine is outfitted with 2 upper and 3 lower leveling rolls.

Hydraulic Pre-Cut

This production line incorporates a hydraulic pre-cutting device, simplifying the replacement of steel coils with varying widths and thicknesses, while simultaneously minimizing coil waste.

Roll Forming Machine

The roll forming machine stands as the pivotal component of the entire production line. This machine employs cast-iron structure made from whole piece solid steel and is driven by chain system. It has the capability to produce various sizes with uniform height. Workers input planned sizes on the PLC control screen, enabling automatic adjustment of forming stations to precise positions. Experienced workers typically take around 60 minutes to complete the entire process of changing dimensions, including the automatic movement of the forming stations and the manual replacement of the steel coil.

The A point serves as a crucial forming point for alterations in width. The movement of roll forming stations on the rails shifts this key forming point's position, facilitating the production of box beams with different widths.

Gcr15, a high-carbon chromium-bearing steel recognized for its hardness and wear resistance, is utilized for the material of forming rollers. The rollers undergo chrome-plating for prolonged durability. The shafts, made of 40Cr material, undergo heat treatment.

Flying Hydraulic Cut

Following the passage through the roll forming machine, the steel coil progressively takes on force to adopt a C-shaped profile, subsequently being cut to the specified length by a hydraulic cutting machine. And the cutting length error is kept within 1mm. This cutting machine minimizes steel coil wastage and can keep pace with the production speed of the roll forming machine, ensuring uninterrupted operation.

Platform

The first formed C-profile is initially transferred to the end of the upper platform and then pushed onto the lower platform.  The second C-profile undergoes a controlled push onto the middle slope, where a flipping device rotates it, aligning and neatly stacking the two C-profiles vertically.

Guiding rollers ensure alignment of the two C-profiles, and pneumatic push rods push them into the seaming machine.

Seaming machine

The seaming machine is designed with the same structure as the roll forming machine, featuring a cast-iron structure and chain driving system. It can automatically adjust the position of the seaming stations based on the width of the box beam. This machine saves the cost of a welder, as in traditional methods, a worker is hired to weld the two C-profiles into a box beam after roll forming. Subsequently, only labor is required for handling the finished product.

Encoder & PLC

The roll forming machine incorporates a Japanese Koyo encoder that translates sensed coil lengths into electrical signals transmitted to the PLC control cabinet. This precision ensures that cutting errors are kept within 1mm, ensuring the production of high-quality box beams and minimizing waste from incorrect cuts. Operators can manage production speed, set production dimensions, cutting length, and more through the PLC screen. The PLC control cabinet features memory storage for commonly used parameters and protection functions such as overload, short circuit, and phase loss. The language displayed on the PLC screen is customizable to cater to customer requirements.

Hydraulic Station

Our hydraulic station, equipped with cooling electric fans, efficiently dissipates heat, ensuring extended and reliable operation with a low failure rate.

Warranty

Upon shipment, the nameplate clearly indicates the delivery date, providing a two-year guarantee for the entire production line and an impressive five-year warranty for rollers and shafts.