Decoiler with Leveler

This machine integrates the functions of decoiling and leveling. The decoiler features a brake device to adjust the tension of the decoiling roller, ensuring smooth decoiling speed. Additionally, protective leaves made of steel are installed to prevent the steel coil from slipping during the decoiling process. This design provides a cost-effective and high-security decoiling machine.

Subsequently, the steel coil enters the leveling machine. The steel coil used this case is only 1.2mm thick. However, due to the requirement for dense punching, it is crucial to use a leveler to eliminate the curvature of the steel coil, thereby enhancing its flatness and parallelism. This, in turn, improves the quality of the steel coil and the final product. The leveling machine is equipped with 3 upper leveling rollers and 4 lower leveling rollers.

Servo Feeder & Hydraulic Punch

The steel coil then enters an independent hydraulic punch machine. Due to the fast response and minimal start-stop time of the servo motor, it allows precise control of the punching position. Therefore, we use a servo motor to power the feeder for accurate punching.

Limiter

In the middle of the punching and roll forming processes, there is a limiter to coordinate production speed. When the steel coil reaches the lower limiter, signaling that the punching speed is greater than the roll forming speed, the hydraulic punch receives a signal from the PLC control cabinet to stop working. A prompt alarm appears on the PLC screen, and the operator can resume work by clicking on the screen. And, during the few seconds between punching stopping and resuming, the roll forming machine keeps working.

Conversely, when the steel coil reaches the upper limiter, signaling that the forming speed is greater than the punching speed, the roll forming machine stops working. During the few seconds between the roll forming machine stopping and restarting, the hydraulic punch keeps working. The height of the upper limiter can be moved up or down according to customer needs.

This ensures overall coordination and uniform production speed of the production line.

Guiding

Before the steel coil enters the first forming roller, it passes through a guiding bar to keep the steel coil and the machine on the same centerline, preventing distortion of the formed profiles. Guiding rollers are strategically placed not only at the entry point but also along the entire forming line. Measurements of each guiding bar/roller's distance to the edge are recorded in the manual for accurate adjustment if slight displacement occurs during transport or misalignment made by workers during production.

Roll Forming Machine

The roll forming machine is the most crucial part of the entire production line. This roll forming machine has a total of 12 forming stations and features a wall panel structure and chain driving system. It is noteworthy that this roll forming machine is a double-row structure, capable of producing two different shapes – upright and beam for light-duty shelving. Although these two rows cannot work simultaneously, it offers flexibility for varied production needs. Protective covers are installed on the chain to ensure worker safety. The roll forming machine is tested using steel coils with the same yield strength as those used in customer production, ensuring immediate production convenience upon delivery.

The material of the forming rollers is Gcr15, a high-carbon chromium bearing steel known for its hardness and wear resistance. Chrome plating on the roller surface extends its lifespan, while the shafts are made of heat-treated 40Cr material.

Flying Hydraulic Cutting & Encoder

The roll forming machine incorporates a Japanese Koyo encoder, converting the sensed steel coil length into electrical signals transmitted to the PLC control cabinet. This allows the cutting machine to control cutting errors within 1mm, ensuring high-quality products and minimizing waste from incorrect cuts. "Flying" refers to the ability of the cutting machine to move back and forth at the same speed as the roll forming machine during cutting, allowing continuous operation of the roll forming machine and increasing the overall production line capacity.

Hydraulic Station

The hydraulic station is equipped with a cooling electric fan for efficient heat dissipation, ensuring prolonged, low-fault operation, and durability.

PLC

Workers can control production speed, set production dimensions, cutting lengths, etc., through the PLC screen. The PLC control cabinet includes protective functions such as overload, short circuit, and phase loss protection. The language of the PLC screen can be customized in a certain language or multiple languages according to customer needs.

Warranty

Before delivery, the delivery date is indicated on the nameplate, starting a two-year guarantee for the entire production line and a five-year warranty for rollers and shafts.