Flow chart

Hydraulic decoiler with leveler--Servo feeder--Hydraulic punch--Roll forming machine--Hydraulic cut and stamping--Out table

Main Techinical Parameters

1. Line speed: 0-4 m/min, adjustable
2. Profiles: Multiple sizes-same height, different width and length                      
3. Material thickness: 0.6-0.8mm (in this case)
4. Suitable material: Galvanized steel
5. Roll forming machine:Cantilevereddouble-wall panel structure and chain driving system.
6. Of forming station: 13
7. Cutting system: Cut and bend at the same time, roll former doesn’t stop when cutting and bending.
8. Changing size: Automatically.
9. PLC cabinet: Siemens system.

Hydraulic decoiler with leveler

The core expansion is adjustable to accommodate different steel coil inner diameters ranging from 460mm to 520mm. During uncoiling, the outward coil retainers are in place to prevent the steel coil from slipping off the decoiler. This is to protect the safety of the workers.

The leveler has a series of leveling rollers that progressively flat the steel coil to remove the residual stresses.

Servo feeder & Hydraulic punch

• Independent Hydraulic Punching

This punching system operates independently without sharing the same machine base with the roll forming machine, ensuring seamless and uninterrupted performance of roll forming machine.  The feeder gets power from the servo motor, whose minimal start-stop time delay allows for precise control over the steel coil's advancement in the coil feeder, ensuring accurate and efficient punching.

(2)Optimized mold solution

The punched holes on the shelf panel are categorized into notches, functional holes, and bottom continuous holes. Considering the different frequencies of these hole types within one shelf panel, the hydraulic punch machine features four dedicated mold for the four types of holes. This solution is purpose-built to efficiently complete each one type of punching, enhancing overall efficiency and productivity.

Encoder & PLC

The encoder converts sensed steel coil lengths into electrical signals transmitted to the PLC control cabinet. Within the control cabinet, operators can control production speed, single production output, cutting length, and more. With precise measurement and feedback from the encoder, the cutting machine can control cutting errors within ±1mm.

Roll forming machine

Before entering the roll forming machine, the steel coil passes through guiding bars. The two guiding bars are adjustable based on the width of the steel coil, ensuring the alignment of the steel coil with the production line machinery on the same center line. This alignment is crucial for maintaining the straightness and load-bearing capacity of the shelf panel.

This forming machine features a double-wall cantilever structure. Due to the need for forming only on two sides of the panel, a cantilever roller design is employed to save roller material. And the chain driving system leads the rollers and imparts force to the steel coil, facilitating the advancement and forming of the steel coil.

The machine is capable of producing shelf panels of various widths. Workers input the desired dimensions on the PLC control cabinet panel. Upon receiving the signal, the forming station on the right side automatically moves along the rails, and the forming points on the steel coil change with the movement of the forming station and forming rollers.

An Encoder is also equipped to sense the distance of the forming station's movement, ensuring accuracy when changing sizes. Additionally, two position sensors are included, detecting the farthest and nearest distances the forming station can move on the rails. The farthest position sensor prevents excessive movement of the forming station, preventing slippage, while the minimum position sensor prevents the forming station from moving too far inward, avoiding collisions.

Hydraulic cutting and bending

The shelf panels produced on this production line feature double bends on the wide side. We've devised an integrated cutting and bending mold, allowing for cutting and subsequent double bending in a single machine. This design not only saves production line length and factory floor space cost but also reduces production time.

During cutting and bending, the cutting machine base can move backward and forward in sync with the roll forming machine's production speed, ensuring uninterrupted production and boosting efficiency.

If you're interested in single-bend shelf panels, click the image to learn more about the detailed production process and video.

Key differences:

• Double-bend type provides superior durability, while single-bend type also meets storage needs adequately.
• Double-bend type edges are not sharp, making them safer to use.

• 
  Hydraulic punch
• 
  Transport platform for triple folded shelf panel
• 
  Triple folded shelf panel
• 
  Decoiler and leveler
•  
•  
•  
•