Box beam roll forming machine

Box Beam roll forming machine

A. Main data

1. Material specification：thickness 1.5-2.0mm，strength yield≤G300MPa
2. De-coiler：5T hydraulic decoiler
3. Working speed：0-35min ( forming C section speed)
4. If the whole line speed, it is about 3pcs/min for box beam.
5. Roller step：19 steps
6. Roller material: GCr15 quenching treatment HRC 58-62°
7. Main shaft material: 45# high quality steel with thermal refining treatment.
8. Main shaft diameter:￠85mm
9. Main motor power：30KW
10.  Structure mode：Column structure, gearbox drive
11. Hydraulic station motor power：5.5 KW
12. Servo motor power: 4 KW
13. Electronic system：The whole line use PLC to control, PLC is Siemens PLC.
14. Cutting mode：Hydraulic following cutting system
15. Machine size: 16000x1300x1200mm (LxWxH)
16. Need 2x40HQ container
17. Color: Blue and orange ( or customized)

2. Main technical parameters:

Input strip coil width:/ (according to final design)

Strip coil thickness: 1.5-2.0mm

Strip coil material: GI

Roll forming speed: 0-35m/min( C section forming speed)

The minimum rolling piece length: 1000mm

The rolling piece straightness tolerance: 1.0-1.5mm /1500 mm

The rolling piece angle tolerance: ≤±1.5/1000mm

The rolling piece cutting length tolerance: 10m±1.5mm

Process for Fully automatic Beam roll forming machine:

5T decoiling→guide & feeding→leveling →Roll forming → Straightening → hydraulic track cutting → Roller table conveyor→automatic overturning→conveyor→hugging & roll forming→ Runout table

3. Description for main equipments:

 5Tmanualdecoiling machine:

Coil inner diameter: φ508mm;

Inner diameter tension range: ф480-520 mm;

Coil max outer diameter: φ1300mm;

Loading capacity: ≤5T;  Expansion method: by 5T hydraulic

The main roll forming machine:

Main technical parameters:

Main motor power: 30KW

Forming steps: 19 steps

Forming speed:0-35m/min 

Hugging speed: 4-5pcs/min

Roller material: GCr15, with quenching hardness HRC58-62°

Roll forming machine structure: with Steel housing structure, by gear boxes driving;

Main shaft diameter: ¢85mm

Cutting mode: Hydraulic following cutting system.

Width adjustment: by PLC automatic

3.4. The Straightening device:  

The last step of rollers is overpressure rollers. Before this step of rollers, two rollers are set, which can be corrected and straightened by two-way adjustment. This ensures that the products with no torsional deformation.

3.5. Hydraulic track Cutting device:

It is adopted with Servo tracking hydraulic cutting:

a. Type: hydraulic mould cutting (equipped with 6 sets of cutting moulds).

b. Structural features: the cutting is an independent device, the length is determined by PLC, and the cutting length can be set by itself. The cutting end face has small deformation and high production efficiency.

3.6.Roller conveyor and automatic overturning device:

The roll formed profiles are transported to the designated position by the powered roller conveyor, and then the profiles are overturned by the pneumatic device, so that the two profiles are always in a positive and negative state. Then it is fed into the roll forming machine through the conveying roller and then hugged together.

Main technical parameters for hugging & roll forming machine:

Motor power for roll forming machine: 15kw

Forming steps: 5 steps

Production speed of main machine: 4-5pcs / min

Roller material: Cr12Mov, with quenching hardness HRC58-62 °

Roll forming machine structure: with Steel housing structure, by gearbox driving

Main shaft diameter: ￠80mm

3.8. Electric controlling system:

It is adopted with Siemens 7” touch screen; Germany SiemensPLC; Japanese YaskawaFrequency converter; and Schneider Low voltages.

a. The whole line adopts with PLC controlling, LCD touch screen, human-machine interface (HMI). it can realize the interaction between human and PLC. The operator can automatically operate through the set program (programmable control), monitor the control process, modify the control parameters, and can monitor the equipment running status, operating parameters and fault indications in real time. The length is digitally set and can be adjusted.

b. It can operate by manual/automatic modes. With manual and automatic exchanging function: In the manual state, it can run the individual single machine, which is convenient for maintenance; in the automatic state, to have the full production line running; with emergency stop button, it is easy to handle the emergency, and ensure equipment and operators Safety.

c. There is a manual operation panel near the machine to facilitate the worker's operation.

Layout