Automatic size changement C-shape rack roll forming machine
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Profile
Cross bracing plays a vital role in rack systems, bolstering support and stability between two upright frames. Crafted from durable black steel with a thickness typically ranging from 1.5 to 2.5mm, post-forming paint application serves to augment corrosion and rust resistance, ensuring longevity and reliability.
Real case-Main Technical Parameters
Flow chart: Decoiler–Guiding–Leveler–Pre cut–Roll forming machine–Out table
- 1.Line speed: 0-15m/min, adjustable
- 2.Dimensions in real case: Multiple width 80-300mm, fixed height 50mm
- 3.Suitable material: Galvanized steel
- 4.Material thickness: 1.5-2mm
- 5.Roll forming machine: Cast-iron structure and chain driving system
- 6.Cutting system: Cut before roll forming machine, with hydraulic power.
- 7.PLC cabinet: Siemens system.
Real case-Machinery
1.Decoiler*1
2.Leveler(Equipped on the roll forming machine)*1
3.Hydraulic pre-cut machine*1
4.Roll forming machine*1
5.Out table*2
6.PLC control cabinet*1
7.Hydraulic station*2
8.Spare parts box(Free)*1
Real case-Description
- Decoiler
Usually, the decoiler serves as the first component of the production line. Its press arm is capable of securing the steel coil, preventing injury from coil recoil during coil changeovers. Outward coil retainer devices further prevent coils from sliding off the mandrel.
Guiding
The guiding rollers will properly guide the steel coil into the forming rollers to keep the alignment between the steel coil and the roll forming machine, minimizing any potential bending or deviation.
Leveler
The thickness of the cross bracing reaches 2.5mm, and only when it is perfectly straight and not twisted can it provide the best stability for the rack frame. The leveling machine can flatten the steel coil, release internal pressure, making it easier to shape and form straightly. In this production line, the leveling machine is set on the roll forming machine base, which can save floor space and reduce land costs.
Pre-cut machine
Compared to post-cutting, pre-cutting before forming makes no waste. This solution facilitates easier replacement of steel coils of varying widths for producing multiple sizes on the same production line, without causing any waste.
Roll forming machine
The roll forming machine is the most critical component of the entire production line. It utilizes a robust cast-iron construction for the forming station, crafted from a solid piece of steel. The rotation of the forming rollers is driven by a chain system.
The material of the forming rollers is Gcr15, a high-carbon chromium bearing steel renowned for its excellent hardness and wear resistance. The rollers are chrome-plated to extend their service life. The shafts are made of 40Cr material and undergo heat treatment.
Reinforcements are incorporated at the bottom of the profile to enhance its strength. This roll forming machine can produce cross bracing with a width of 80-300mm and a height of 50mm. By inputting the desired dimensions into the PLC control panel, the forming station moves along the rails to the correct and precise position. The forming point also adjusts as the forming station moves.
For safety of the movement of forming stations, 2 distance sensors are set on the machine base, corresponding to the outermost and innermost positions that the forming stations can be moved to. For the sensors, the sensing point is the here at the base of the forming stations. The innermost sensor is to prevent the forming stations from getting too close and causing roller collisions. The outermost sensor is to prevent the forming station from disengaging from the rails and falling.
Hydraulic station
The hydraulic station comes fitted with cooling fans designed for efficient heat dissipation, guaranteeing uninterrupted operation and boosting productivity. Renowned for its low failure rates, this hydraulic station is built to last, ensuring long-term durability.
PLC control cabinet & Encoder
The encoder converts the sensed length of the steel coil into electrical signals transmitted to the PLC control cabinet. Within the control cabinet, production speed, individual production output, cutting length, and other parameters can be managed. With precise measurements and feedback from the encoder, the cutting machine can control cutting errors within ±1mm.
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