Highway Guardrail U Post & Spacer Roll Forming Machine

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Details
Description

The profiles produced on this production line are all in U-shaped forms, specifically the U post and spacer block within the guardrail system. The spacer block serves as a resistance block installed between the post and guardrail beam, providing cushioning upon impact.

 

Typically, U posts and spacer blocks are made of 5mm cold-rolled or hot-rolled steel, with hole punching preceding the forming process. These holes are reserved for screw and nut installation.

Real case-Main Techinical Parameters

Flow chart

5T Hydraulic decoiler--Guiding--Leveling--Hydraulic punch--Roll forming machine--Hydraulic cut--Out table

 

Main Techinical Parameters

  1. Line speed: 0-6m/min, adjustable
  2. Profiles: U post channel and Spacer
  3. Material thickness: 5mm (in this case)
  4. Suitable material:Hot rolled steel, cold rolled steel
  5. Roll forming machine: Cast-iron structure and gearbox driving system.
  6. Of forming station: 16
  7. Punching system: Hydraulic, roll former stops when punching.
  8. Cutting system: Hydraulic, roll former stops when cutting.
  9. PLC cabinet: Siemens system.

Real case-Description

Hydraulic decoiler

Engineered with efficiency and safety in mind, the hydraulic decoiler is driven by a powerful hydraulic station. Featuring an outward coil retainer, it prevents the steel coil from slipping off, while the press arm firmly secures the coil, ensuring worker safety by preventing unexpected springs up.

 

Leveler

By alleviating internal stress within the coils, it optimizes them for punching and forming. Integrated with the forming machine base, the leveler saves valuable floor space and reduces land costs in your production line setup.

 

Hydraulic punch

The hydraulic punch is capable of punching holes in steel coils up to 5mm thick, ready for screw installations. Connected to the roll forming machine base, it ensures precise operations, albeit requiring brief pauses during punching.

 

For increased production speeds, standalone hydraulic punch solution is also available.

 

Roll forming machine

At the heart of the production line lies the roll forming machine. Its robust cast-iron structure effortlessly handles 5mm thick steel coil forming. All roll forming rollers are driven by the gearbox system, crafted from Gcr15, the high-carbon chromium-bearing steel rollers offer exceptional hardness and wear resistance, further enhanced by chrome plating. Meanwhile, heat-treated 40Cr shafts guarantee durability and reliability even under the most demanding conditions.

 

Encoder & PLC

Precision meets control with the encoder and PLC system. Seamlessly converting steel coil length into electrical signals, the encoder provides accurate feedback to the PLC control cabinet. The production speed, quantity per cycle, cutting lengths can all be set on the PLC control cabinet, and limit the cutting errors within ±1mm. Customers can set the cutting length according to their needs through the operation panel.

 

Hydraulic cut


Each cut leaves behind smooth, burr-free edges, eliminating waste while ensuring impeccable precision. This way, it can save costs for customers. It should be noted that the roll forming machine pauses during each cutting operation.

 

We also offer one higher speed solution that the roll forming machine doesn't stop when cutting if you need.

 

Hydraulic station

Efficiency meets reliability with our state-of-the-art hydraulic station. Equipped with cooling electric fans, it efficiently dissipates heat, maintaining optimal working temperatures for prolonged operations. With minimal failure rates, our hydraulic stations guarantee durability and longevity, ensuring uninterrupted production workflows.

Technical specification

Two Waves/Three Waves Highway Guardrail Roll Forming Machine

No.

Item

Specification

Optional

1

Suitable material

Type:Galvanized Coil, PPGI, Carbon steel Coil

 

 

 

Thickness(mm):4-5

 

 

 

Yield strength: 250 - 550MPa

 

 

 

Tensil stress( Mpa):G350Mpa-G550Mpa

 

2

Nominal forming speed(m/min)

15

Or according to your requirement

3

Forming station

10-12

According to your profile

4

Decoiler

Hydraulic decoiler

 

5

Main machine motor

Sino-German Brand

Siemens

6

PLC brand

Siemens

Panasonic

7

Inverter brand

Yaskawa

 

8

Driving system

Gearbox drive

Chain drive

9

Rollers’ materail

Cr12

GCr15 or #45 Steel

10

Station structure

Forged Iron station

 

Wall panel station
Or torri stand structure

 

11

Punching system

No

Hydraulic punching station or Punching press

12

Cutting system

Post-cutting

Pre-cutting

13

Power supply requirement

380V 60Hz

Or according to your requirement

14

Machine color

Industrial blue

Or according to your requirement

More Pictures
 
Profile drawings
 
 
Optional configuration
  • Out table
    • Non-powered
    • Auto stacker
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  • Cutting
    • flying shear
    • Saw cutting
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  • Driving
    • chain drive
    • gearbox drive
    • gearbox drive with coupling
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  • Stands
    • wall panel
    • torri stands
    • forged iron
    • ruler
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  • Punching
    • punching press
    • hydraulic punching station
    • roller punch
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  • Feeding
    • Leveler
    • servo feeder
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  • Decoiler
    • manual decoiler
    • hydraulic decoiler
    • double head decoiler
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