Flow chart

Decoiler-Guiding-Leveler-Pre Punching-Roll former-Welder-Hydraulic cut-Out table

Hydraulic decoiler

We install a press-arm on the decoiler to press the steel coil when replacing the coil, which prevents the steel coil from unexpectedly unwinding and potentially causing harm to workers. Additionally, we have incorporated protective iron-leaves to prevent the steel coil from slipping during the unwinding process. This design ensures the safety of both workers and the integrity of the steel coil and the machine.

Guiding&Leveler

The steel coil then passes through four guiding rollers, ensuring that it remains on the same centerline as the machines, preventing any bending of the profiles. As step beams play a critical role in bearing loads, they must remain free from distortion. Notably, multiple guiding rollers are placed throughout the entire roll forming line. Following this, the steel coil enters the leveling machine, which eliminates irregularities in the coil, enhancing both its flatness and parallelism. This process significantly improves the overall quality of both the steel coil and the step beam produced.a

Pre Punching & Hydraulic cutting

Before the forming process, the steel coil are punched a notch on both sides. These notches gradually converge during the roll forming process, eventually merging into a rectangular hole. During the cutting process, the hydraulic cutting blade descends vertically through this hole to cut the step beam. This explains why there is no bending at the ends of the step beam, even though it is a closed shape.

Additionally, we can also provide another cutting method, which is saw cutting. Saw cutting tends to be a bit slower and require blade replacement. However, it delivers more superior cutting results than traditional hydraulic cutting. Therefore, we've innovatively introduced a notching technique to enhance the efficiency of hydraulic cutting. We will provide the best cutting solution based on customer needs and our professional experience.

Roll former

The steel coil with notches then proceeds to the roll forming machine, which can produce various sizes of step beams with heights ranging from 70mm to 140mm. Furthermore, precise control of the left and right roll forming stations is achieved through PLC and encoders, ensuring that both sides move together in perfect synchronization. This design guarantees that the centerline of the steel coil and machines remains stable, resulting in superior straightness and alignment for the produced step beams.

By moving the forming station, the force point of the steel coil was changed, ultimately achieving multi-size production.

For every 10mm of height of the largest step beam required to be produced, the diameter of the key forming roller must also be increased by 10mm. This is also one of the factors that affects the price of the machine, because the material used for the rollers will increase.

Welder

Step beams are roll formed from a flat steel coil, gradually taking on a closed shape. To ensure safe load-bearing capabilities in shelf systems, the closed interface should be kept for a long time and should not open. So welding at the seam is crucial. After roll forming, we have a welding machine welded at approximately 10 cm intervals, we call it spot welder. This device saves on solderer labor costs for our customers.

Additionally, we also offer a full welding configuration for enhanced welding quality, which we will discuss further. We will give you the best welding solution based on professional experience and customer needs.

Through our PLC control system, step beams can be cut to any length and quantity. With encoders in the roll forming line, the length cutting is extremely precise, within an error of 0.5mm, minimizing any waste due to inaccurate cutting.

Finally, the step beam is transported to the out table after hydraulic cutting.