Manual Decoiler

The manual decoiler is equipped with a brake device to adjust the tension of the core expansion ranging from φ490-510 mm and control the smoothness of the unociling process. The 1.9mm steel coil used in this case poses a risk of sudden poping open during the uncoiling process. To enhance safety, a press arm is installed to secure the steel coil, and protective blades made of steel are added to prevent steel coil slipping out. This design offers a cost-effective and high-safety solution.

The manual decoiler has no power. For higher production capacity requirements, we provide an optional hydraulic decoiler powered by a hydraulic station.

Guiding & Digital display

The primary function of guiding rollers is to maintain alignment between the steel coil and the machines, preventing distortion of the step beam and participating in part of the roll forming process to prevent rebound deformation of the steel. The straightness of the step beam is crucial for product quality and affects the load-bearing performance of the entire racking system. Guiding rollers are strategically placed not only at the beginning of the roll forming machine but also at various points along the entire roll forming line.

Digital display devices facilitate the convenient recording of the correct position of the guiding rollers. And measurements of the distance from each guiding roller to the left and right edges of the roll forming machine are recorded in the manual, allowing for easy adjustments based on these data even if slight displacements occur during transportation or production.

Leveler

Subsequently, the steel coil enters the leveler. With a coil thickness of 1.9mm, it's essential to eliminate the curvature of the steel coil, improving its flatness and parallelism for the quality of step beam. The leveler is equipped with 3 upper and 4 lower leveling rollers.

Roll Forming Machine

The roll forming machine is the most critical part of the entire production line, with variable speed control through a (Japanese brand) Yaskawa inverter ranging from 0 to 10m/min. This roll forming machine comprises 26 forming stations, utilizing a wall-panel structure and chain-driving system.

It can produce different sizes with a width of 66mm and a height ranging from 76.2 to 165.1mm. After the operator inputs the bottom width and height in the PLC control cabinet, the forming stations will automatically adjust to the accurate positions and change the key forming points (A and B points), taking approximately 10 minutes for the size changement. The height changes with the key forming points (A and B points) variation, enabling the production of step beams with different heights.

Gcr15 is used for the material of forming rollers, a high-carbon chromium-bearing steel known for its hardness and wear resistance. The rollers are chrome-plated for extended durability. The shafts, made of 40Cr material, undergo heat treatment for added strength.

Flying MIG Welder

To enhance the lifespan of the step beam and prevent separation at the steel coil joints, welding at the joints of steel coils in a dot pattern, with the spacing between each dot adjustable according to customer requirements. Two welding torches are installed to increase the line speed, and these torches can move simultaneously with the roll forming speed, ensuring continuous operation of the roll forming machine.

Flying Saw Cutting

After roll forming, the step beam enters the cutting machine, utilizing a saw cutting machine due to the closed shape of the step beam. Specialized saw blades ensure high precision and hardness, with a cooling sprayer to protect the saw blades, prolonging the lifespan of the saw blade. The saw cutting speed is slower than hydraulic shearing, but we've set a mobile function to match the roll forming machine's production speed, ensuring continuous operation of the roll forming machine. And the saw cutting machine ensures no waste during steel coil replacement and profile cutting.

Encoder & PLC

A Japanese Koyo encoder in the roll forming machine converts the sensed coil length into an electrical signal transmitted to the PLC control cabinet. A motion controller is installed inside the electrical control cabinet, ensuring no acceleration or deceleration during the forward and backward movement of the cutting machine, thus achieving precise cutting length accuracy. Additionally, the welding marks are stable and smooth, preventing the step beams from cracking, and resulting in a stable and high-quality production. The PLC screen allows operators to control production speed, set production dimensions, cutting length, etc. The PLC control cabinet has a memory storage function for commonly used parameters and offers protection functions such as overload, short circuit, and phase loss.

The language on the PLC screen can be customized according to the customers' requirements.

Hydraulic Station

Our hydraulic station features a cooling electric fan to efficiently dissipate heat, ensuring prolonged and reliable operation with low failure rates.

Warranty

Upon shipment, the delivery date is indicated on the steel nameplate, providing a two-year guarantee for the entire production line and a five-year warranty for rollers and shafts.