Flow chart

Manual decoiler--Guiding--Leveler--Roll forming machine--Flying saw cut--Out table

Main Techinical Parameters

1. Line speed: 5-6meters/min dependes on the cutting length
2. Profiles: Multiple sizes-same height of 50mm, and different width of 100, 110, 120, 130, 140mm
3. Material thickness:1.9mm (in this case)
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: 28
7. Cutting system: Saw cutting, roll former doesn’t stop when cutting.
8. Changing size: 10 minutes automatically.
9. PLC cabinet: Siemens system.

Manual Decoiler

The manual decoiler is equipped with a brake device to adjust the expansion ranging from φ460-520 mm and control the smoothness of the uncoiling process. A press arm is set to avoid the steel coil bulk. Additionally, steel protection leaves are installed to prevent coil slippage during uncoiling. This design ensures high cost-effectiveness and safety.

In this case, a manual decoiler without its own power source is utilized. For higher production capacity demands, we offer an optional hydraulic decoiler powered by a hydraulic station.

Guiding

Guiding rollers play a critical role in maintaining alignment between the steel coil and the machine, preventing distortion of the tube beam. They also contribute to the forming process, averting rebound deformation of the steel coil. The straightness of the tube box beam is crucial for product quality, impacting the load-bearing performance of the racking system. Guiding rollers are strategically placed along the entire forming line to ensure precise positioning. Measurements of each guiding rollers 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

Moving forward, the steel coil enters the leveler. The leveler efficiently eliminates the curvature of the steel coil, enhancing its flatness and parallelism for superior quality in the final product. The leveler is equipped with 3 upper and 4 lower leveling rollers.

Roll Forming Machine

The roll forming machine is the most important part of the entire production line, featuring 28 sets of forming stations with a cast-iron structure made from a whole piece solid steel. Driven by a robust chain system, this machine produces various sizes with the uniform height and different width of 100, 110, 120, 130, 140mm. Workers easily input planned sizes on the PLC control screen, allowing for automatic adjustment of forming stations to precise positions. The automated size change process takes approximately 10 minutes. The movement of forming stations on the rail adjusts the positions of the 4 key forming points, enabling the production of box beams with different widths.

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

Flying Saw Cut

The cross-section of the box beam takes on a closed shape, necessitating the use of a saw cutting to prevent deformation of the cut edges under stress. Saw cutting minimizes steel coil waste, providing smooth cutting surfaces without burrs. Professional saw blades ensure high precision and hardness. Additionally, a cooling nozzle protects and extends the lifespan of the saw blades, preserving their high physical properties for continuous and efficient operation.

While the saw cutting speed is marginally slower than hydraulic shearing, we've set a mobile function to synchronize with the forming machine's production speed, ensuring uninterrupted operation.

Encoder & PLC

A Japanese Koyo encoder within the roll forming machine converts sensed coil lengths into electrical signals transmitted to the PLC control cabinet. This ensures cutting errors are controlled within 1mm, guaranteeing the production of high-quality products and avoiding waste from incorrect cuts. The operators can set production speed, profile dimensions, cutting length, the number of productions, etc on the PLC control cabinet screen.

The PLC cabinet has memory storage function for commonly used parameters, operators don’t have to re-enter parameters before each production. The language on the PLC screen can be customized based on customer preferences.

Hydraulic Station

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

Warranty

On the day of shipment, the current date will be engraved on the metal nameplate, marking the commencement of a two-year guarantee for the entire production line and a five-year warranty for rollers and shafts.