Highway Guardrail Roll Forming Machine

Ⅰ: General properties

·Highway guardrail roll forming machine can produce three waves profile and two waves’ profile.

·When change profile only need to change the last three stations

·For easy to change roller and not need to adjust roller. We will design the two waves roller adopt single shaft with rollers---it means when change three waves profile to two waves profile, just take off the last three stations with shaft, and install the other shaft which with 2 waves profile roller.

·Material thickness: 2.5-3.4mm

Ⅱ:Composition of machine:

·5 ton hydraulic de-coiling 

·Main roll forming machine

·Auto stacker

Ⅲ: Profile, layout & production flow: 

·Thickness range: 2.5-3.4mm

·Coil width: 474mm, 740mm

2 wave profile:

Punching drawing:

3 wave profile

Punching drawing:

·Layout of machine（only for reference, the exactly one will be send to customer in 20 days after confirmed order）

>Working direction base on customer request:

The production flow of equipment:

De-coiling----Feeding---leveling---punching---roll forming---cutting---auto stacker

Ⅳ: Technology of Composition of machine

1. 5 ton hydraulic de-coiler
·Steel coil width: from 474-740 mm;
·Internal diameter of coil: variable, from 470 mm to 510 mm
·Maximum coil weight: 5000 Kg;
·Oil cylinder dia:120mm
·Working speed: 0-15m/min adjustable
·Main motor power: 5.5KW AC motor
·Hydraulic power: 4kw
·Speed controlled by frequency converter brand: Yaskawa
·Quantity: 1

Photo of decoiler:

2: Feeding→leveling→punching→roll forming →post cutting

>Feeding and leveling

·Feeding the sheet to the guide roller (it is adjustable by right and left).

·Feeding roller: diameter is ￠180 mm, material is 40Cr steel, HRC48-52.°

·Leveling roller: upper is 3 rollers, down is 4 rollers (total is 7 stations), material is 40Cr steel, HRC48-52°

·Diameter of leveling roller: 76 mm

·Sample photo for reference

>Punching

·Using hydraulic punching, pre-punching

·Oil cylinder diameter: ￠180 mm

·Working pressure: 30MPa

·Mould material: Cr12,  quenched 58°-62°

·Hydraulic power: 22kw

·Punching station: 2 stations

·The base should be with scrap hole

·Sample photo for reference

>Forming Section

·Main motor power: 45kw

·Station: adopt guide pillar stations

·Sample photo for reference

·Decelerating motor: BWD14-43-45KW

·Transmission: by gear box: 200*500(outside is cast iron, surface needed polish and paint. Inside is 60# forge and press metal)

·Sample photo for reference

·Main shaft dia: ￠100mm   material: 45﹟forge steel

·Roller material: GCR15 quenched 58°-62°, black oxide coating

·Roll station: 20 stations (include feeding two feeding stations)

·Sample photo for reference

·Change the last stations of rollers to change 2 waves into 3 waves

·One machine can produce three waves profile and two waves’ profile.

·When change profile only need to change the last three stations

·For easy to change roller and not need to adjust roller. We will design the two waves roller adopt single shaft with rollers---it means when change three waves profile to two waves profile, just take off the last three stations with shaft, and install the other shaft which with 2 waves profile roller.

·Sample photo of frame for reference

★: The frame for the roll forming part is the normal frame which we have made before.

·Sample photo of frame for reference

·Roller thickness: 2.5-3.4mm

·Timing by transducer: 5m--12m/min(not including punching)

·Transducer: Panasonic made in Japan. 380V 50HZ

·Computer: PLC (Panasonic)

·Computer operating panel: touch screen

>Post cutting system

·Profile transversal cutting device units allowing to cut the bent profile without damaging the metal coating and to assure a smooth cut: included;

·Feeding of the last cut profile from the equipment: automatic if the length of the last profile is not less than 1500 mm;

·Cutting after forming: Cut the sheet after roll forming to required length

·Uses three hydraulic cylinders for operation shall include a flow regulator to achieve a uniform lowering knife.

·Material of blade:Cr12, 58-62 HRC hardness

·Cutting power by hydraulic, 22KW

·Working pressure: 30Mpa adjustable

·Length measuring: Automatic encoder length measuring, brand: Omron

·The cutting sequence is also contained and controlled by the same PLC program

·Tolerance of length: +/- 1.5mm for each piece end product

·Quantity: 1

Photo of cutting:

>Control Panel (Panasonic)

·Full line is controlled by PLC control system, touch screen operation to achieve the human and PLC interactive. The operator can monitor the setting program (programmable control) and modify the parameter to control the line. Also can check the running status, parameter and error indication etc.

·Operation type: manual /auto two type switch. In manual position: can run the each part of the machine. In auto position: can run the full line. The emergency stop ensures the safe of the equipment and operator.

·Machine side is equipped with the manual operation control panel for convenient worker to operate.

·Entire line surveillance function: to reach surveillance production line movement condition, realizes to various locations production condition surveillance.

·Has the failure detection function: Carries on to the production line signal succession examines, the checkup according to sequence, discovers the mistake, and giving the alarm to stop the machine.

·Two language: Chinese and English

·PLC brand: Panasonic

·Frequency converter brand: Yaskawa

·Touch screen: MCGS

>5m auto stacker:

·Length: 5 meter

·Motor power: 3kw

Sample photo for reference:

3: Spare part list

4: Brand for complete line:

·PLC: Panasonic

·Limit switch : Panasonic

·Touch screen：MCGS

·Transducer: Yaskawa

·Button and Contactor：Schnerder

·Encoder：Omron

Photo of the complete line: (just for reference)

Finished product:

Packing & Delivery

·Deliver time: take goods after receive deposit 90 days

·Packing: suitable of ocean transportation

Warranty

·Warranty: 1 year warranty from date of shipment

·Guarantee:

1: Guaranteed against malfunctions due to manufacturing defects for 1 year after date of shipment. Repairs will be made free of charge.

2: Repairs will not be performed free of change even during the guarantee period in the follow circumstances

-  Damage occurs due to a natural disaster

-  Malfunction occurs due to user error

-  Malfunction occurs due to modifications

-  Malfunction occurs due to further movement or shipment after installation

3:Air ticket, transportation cost, hotel, meals and 100$ per day shall be for purchaser’s account if manufacturer’s engineer has to be send to purchaser’s factory to maintain the machine during the guarantee period.

7. Payment Term

30% deposit by T/T in advance and 70% balance after inspection confirmation before shipment