Quick Detail
Place of Origin
HS-CODE
84-
Package & Delivery Lead Time
Detailed Description
Description：
（1）Load coils onto the double head decoiler’s expansion system.
（2）Start the equipments and feed the material into the flattener manually.
（3）The material after flattened is accurately fed into the mechanical puncher for ordinal punching. The accumulated tolerance of the central distance of holes is subject to the feeding system.
（4）The front and rear material stores are used to adjust the non synchronization caused by the discontinuous moving in punching.
（5）The material after flattened and punched is rolled through the specially designed tooling station by station to form the required shape.
（6）At the end of the roll former a rectifying system is mounted to rectify the shape and straightness of the formed product to the final profile.
（7）The hydraulic cutter controlled by photoelectric switch and measuring system is used to cut the finished material into required length.
（8）The finished products, counted by the PLC automatically, are conveyed to the simple run out table where the workers can take them for package or to the warehouse.
Ⅱ. Main Configuration and Technical Details
The line is mainly consist of one double head decoiler, one flattener, one front material store, one serve feeder, one mechanical puncher, one roll former, one rectifying system, one cutting system, one hydraulic system, one electrical controlling system and one run out table, etc.
1. Double Head Decoiler
This decoiler with a steel welded structure, decoiling passively, adopts coils with ID of φ500mm. It is operated manually under which it can load coils on both the heads which can be circumgyrated.
2. Flattener
According to the flatness accuracy requirement, the flattener, calculating under the theory of minimum distortion is used to flatten, convey and draught the material. The flattener has 5 flattening rollers, 2 feeding rollers and 2 delivering rollers. And the distance of the rollers can be adjusted according to the thickness and rigidness of the material to ensure an ideal flattening function. The flattening rollers are made of heat treated high alloy steel to ensure the rigidity and abrasion proofed characteristics.
3. Front and Rear Material Stores
In order to match the speed of intermission feeding while punching and the continuous feeding while roll forming for continuous production, in front and rear of the puncher material stores are supplied, in which the length of the material naturally sinks is able to provide a cushion for the interval of punching and the continuing of the roll forming. The dimension of the material stores depends on the forming speed. Photoelectric sensor equipment, mounted in the material stores, can stop or re start the roll former when the accumulated material monitored is too long or less.
4. Intermission Feeder
This system, adopting sever roller feeder and computer controlling panel on which by input the feeding length the required feeding distance can be reached, is to feed the material into punching area in high accuracy.
5. Mechanical Puncher
The puncher, adopting JF21-63 pressing system, combination pneumatic friction clutch, pressing brake and vertical axes, has an advantage of good rigidity, high accuracy, smooth clutching, flexible moving and low noise.
6. Roll Former
The roll former is designed to have 20 forming stations sitting on steel structured frame. Every station is driven by gear box through universal shaft. The material is rolled through the roll former station by station to form the shape gradually by the rollers of GCr15 bearing steel, which were designed in Germany Roller Designing Software COPRA, processed on CNC lathes and heat treated at HRC56-60 to achieve an accurate profile.
7．Main Parameters of the machine:
No
Item
Parameter
1
Material thickness (mm)
1.9/2.25
2.65/3.0
1.9/2.25
1.9/2.25
1.9/2.25
2
Coil width Max
400mm
3
Product Dimension
M100×105
M100×80W
M100×80
M75×80
M76×62
4
Forming Speed Max
10-15m/min
5
Main Motor
22KW, 3 Phases，380V, 60Hz
6
Reducer
Cycloid Pin
7
Station
20 Forming Stations
8
Distance B/t Stations
550 mm
9
Roller Material
GCr15, HRC56-60
10
Shaft Material
45#，Tempering Treatment
11
Diameter of the Shaft
￠80, Surface Milled
12
Driving Shaft
EQ140 Universal Shafts
13
Gear Box
GY170 Equal Geared
The roll former is designed according to profile of M100×105, and other profiles can be formed by changing rollers or entire sections.
8. Rectifying System
In order to abolish the bend and retortion of the profiled panel, the rectifying system is provided at the end of the roll former, which adopts a structure of Adjustable 4-roller Cross type.
9. Hydraulic Cutting System
Hydraulic cutting machine comprises tracking car, position returning system, mechanical positioning equipment, photoelectric sensing switch, controlling system, hydraulic cylinder and profiled panel cutting tool. When the profiled panel runs to the tracking car, the controlling system according to the signal sent by the photoelectric sensing switch drives the positioning hand on the mechanical positioning equipment into the pre punching hole of the roll formed profile, thus makes the tracking car move accordingly. After that the hydraulic cylinder, reacting to the signal from the controlling system drives the upper cutting die to move downward to conclude the cutting performance, after which the cutting die lifts upward immediately and, the positioning hand pulls back from the pre punching hole of the roll formed profile and the tracking car returns at the quickest. This is one complete action which will be repeated continuously to conclude cutting task on the production line.
10. Hydraulic System
The hydraulic system consists of hydraulic controlling station, high pressure oil pump, oil tank, etc, with a driving power of 7.5KW and system pressure of 16MPa.
11. Electrical Controlling System
The whole line adopts PLC controlling system. And on the touch screen, tasks can be set in groups.
Flattener: the flattener works continuously while the puncher works intermittently. And the front material store is used to balance the length of material to maintain a continuous production.
Roll Former: the non-synchronization between the puncher and roll former is balanced by the rear material store to maintain a continuous production.
Measure and Cut: the encoding wheel measures the length and speed of the rolling panel; the photoelectric switch positions at the benchmark of holes; the position code of the tracking car reflects the position of the car; PLC controls the continuous punching and cutting to length.
Controlling Panel: it adopts touch screen, on which tasks can be set in groups to control the whole line. And it has an emergency button to stop the whole line at a press at emergent situation.
12. Material Automatic Controlling System
The system has the function to control the synchronization of the material feeding and roll forming. In the material store, the photoelectric monitoring equipments are mounted to control the volume of the material.
Front Material Store: when the material touches the lower point, the flattener stops working; when the material leaves the lower point up to the upper point or the middle point, the flattener starts to feed; the speed of feeder is designed a little bit larger than that of the feeder of the puncher.
Rear Material Store: when the material leaves the upper point down to the middle, the roll former starts to work; otherwise, when the material goes up to the upper point, the roll former stops to wait for the material.
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