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Cross bracing is an essential part of heavy-duty rack structures, diagonally supporting between two uprights. It prevents the racks from wobbling and maintains alignment under heavy loads. It is typically made from hot-rolled steel, cold-rolled steel, or galvanized steel with a thickness of 1.5-2 mm.

 

The traditional production solution of cross bracing is the bending machine. And now the roll forming machine line, which include uncoiling, leveling, roll forming, punching, and cutting, offers higher automation, helps saving manual cost and has become the preferred choice for many clients.

There are different punching styles based on the installation method:

 

Installation Method 1: A single brace is installed within the rack upright, requiring pre-punched holes at the height of the bracing for screw installation.

Installation Method 2: Two braces are installed within the rack upright, also requiring pre-punched holes at the bottom of the bracing for screw installation.

Real case-Flow chart

Flow chart: Decoiler--Servo feeder--Hydraulic punch--Guiding--Roll forming machine--Flying hydraulic cutting--Out table

Compared to two single-row production lines, a dual-row production line can save you approximately the cost of one forming machine, one decoiler, one servo feeder, and the space required for one production line. Additionally, unlike manual size changes on a single line, the dual-row structure reduces the time cost for changing sizes, thereby improving efficiency.

Real case-Main Technical Parameters

1.Line speed:4-6m/min, adjustable

2.Suitable material:Hot rolled steel, cold rolled steel, galvanized steel

3.Material thickness: 1.5-2mm

4.Roll forming machine: Cast-iron structure

5.Driving system: Gearbox driving system

6.Cutting system:Flying hydraulic cutting, the roll former doesn’t stop when cutting

7.PLC cabinet: Siemens system.

Real case-Machinery
  1. Hydraulic decoiler*1
  2. Servo feeder*1
  3. Hydraulic punch machine*1
  4. Roll forming machine*1
  5. Hydraulic cutting machine*1
  6. Out table*2
  7. PLC control cabinet*1
  8. Hydraulic station*2
  9. Spare parts box(Free)*1
Real case-Description

Decoiler

The central shaft of the decoiler supports the steel coil and serves as an expansion device, suitable for coils with an inner diameter of 490-510mm. The press-arm device on the decoiler holds the coil in place during loading to prevent it from springing open due to internal tension, ensuring worker safety.

 

Hydraulic Punch & Servo Feeder

The hydraulic punch, powered by the hydraulic station, punches holes in the steel coil. Cross bracing is punched at both ends, either on the flange or the bottom, depending on installation requirements. There are standalone and integrated type hydraulic punch machines. The integrated type uses the same base with the roll forming machine, it pauses other machines during punching.

 

This production line uses the standalone version, allowing continuous operation of the decoiler and forming machine during punching, ensuring continuous production. The standalone version features a servo feeder, which, driven by a servo motor, minimizes start-stop delays, precisely controlling the coil's advance length for accurate punching. The pneumatic feed mechanism inside the feeder protects the coil surface from scratches.

 

Guiding

Guiding rollers align the coil and machine to ensure no distortion during forming, cause the straightness of the cross bracing impacts overall shelf stability.

 

Roll Forming Machine

This forming machine features a cast-iron structure and a gearbox system. It should be noted that both rows cannot run simultaneously. For higher production capacity needs, we recommend a separate line for each size.

 

Flying Hydraulic Cutting

The "flying" design allows the cutting machine base to move along a track, enabling continuous coil feeding through the forming machine without stopping for cutting, enhancing overall line speed.

 

The cutting blade should match the profile shape, requiring a separate blade for each size.

 

Optional Device: Shear Butt Welder

The shear welder combines shearing and welding functions, joining new and old steel coils to reduce material waste, coil change time, and adjustment difficulty. It uses TIG welding for smooth and flat joints.

 

Hydraulic Station

The hydraulic station is equipped with cooling fans for efficient heat dissipation, ensuring uninterrupted operation and increased productivity. It is known for its low failure rates and durability.

 

PLC Control Cabinet & Encoder

The encoder converts the measured coil length into electrical signals for the PLC control cabinet. The control cabinet manages production speed, quantity per circle, and cutting length. With accurate feedback from the encoder, the cutting machine maintains a cutting error within ±1mm.

Technical Specifications
Bracing Roll Forming Machine
Machinable Material : A) Zinc-plated steel Thickness(MM): 0.9-2
B) Hot rolled steel
C) Cold rolled steel
Yield strength : 200 - 350 Mpa
Tensil stress : G200 Mpa-G350 Mpa
Decoiler : Manual decoiler * Hydraulic decoiler (Optional)
Punching system : Hydraulic punch station  
Forming station : 14 stands * According to your profile drawings
Main machine motor brand : Shanghai Dedong (Sino-Germany Brand) * Siemens (Optional)
Driving system : Chain drive * Gearbox drive  (Optional)
Machine structure: Wall panel station * Cast Iron (Optional)
Forming speed : 10-15 (M/MIN)  
Rollers’ material : Steel #45, chromed * GCr 15 (Optional)
Cutting system : Post-cutting * Pre-cutting (Optional)
Frequency changer brand : Yaskawa * Siemens (Optional)
PLC brand : Panasonic * Siemens (Optional)
Power supply : 380V 50Hz 3ph * Or according to your requirment
Machine color : Industrial blue * Or according to your requirment
Q&A

1. Q: What kinds of experience do you have in producing bracing roll forming machine?

A: We have exported pallet rack production line to Pakistan, Mexico, Peru, Egypt, Australia and UK etc. In warehouse pallet racking system, we are able to manufacture Upright beam roll forming machine, Box beam roll forming machine, Step beam roll forming machine and Shelf panel roll forming machine etc. We are confident to solve your shelve problem.

 

2. Q: How many sizes can produce this machine?

A: We adopt cast iron structure or cantilever structure with automatic width-change and height-change system. For upright rack beam, our customer usually make 3-4 sizes in one machine. We would check your profile drawings to meet your needs. In this way, we will greatly reduce your cost and time.

 

3.Q: What is delivery time of your bracing roll forming machine?

A: 80 days to 100 days depends on your drawing.

 

4. Q: What is your machine speed?

A: Machine’s working speed depends on drawing specially punch drawing. Normally forming speed is around 20m/min. In addition, considering the complicated punch holes, we recommend that you use a separate punch line to increase production speed, and it’s more cost-effective

 

5. Q: How could you control your machine’s precision and quality?

A: Our secret to producing such precision is that our factory has its own production line, from punching moulds to forming rollers, each mechanical part is completed independently by our factory-self. We strictly control the accuracy at each step from design, processing, assembling to quality control, we refuse to cut corners.

 

6. Q: What is your after-sales service system?

A: We don’t hesitate to give you a 2 years warranty period for whole lines, 5 years for motor: If there will be any quality problems caused by non-human factors, we will handle it immediately for you and we will be ready for you 7X24H. One purchase, lifetime care for you.

 

 

Purchase Service
Profile drawings
Optional configuration
  • Out table
    • Non-powered
    • Auto-stacker
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  • Cutting
    • Saw cutting
    • fast flyting cutting
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  • Driving
    • chain driving system
    • gearbox driving system
    • Gearbox with couplings
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  • Stands
    • Torri Stands
    • Forged Iron Stands
    • Wall Panel
    • ruler
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  • Punching
    • Hydraulic punching station
    • Fast Roller Punching system
    • Punching press
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  • Feeding
    • Servo feeder
    • Leveler
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  • Decoiler
    • Motorized&Hydraulic decoiler
    • Double head motorized decoiler
    • Manual Decoiler
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