Ⅰ、 Overview
The storage rack roll forming machine uses rolled metal sheets as raw materials, and after uncoiling, leveling, punching, continuous roll-forming, and automatic fixed-length cutting, it is made into plates of specific shapes and specifications. The whole machine adopts PLC control and AC frequency conversion speed regulation technology to achieve continuous automatic production. It is an ideal production equipment for the steel structure and metal cold bending processing industry.
When producing different specifications, this production line only needs to replace the forming frame. Since it shares the same unwinding and leveling mechanism, servo punching mechanism (hydraulic), main drive base, servo tracking punching mechanism, hydraulic control system and PLC control system, it achieves the purpose of cost saving and rapid production change.
Ⅱ、 Profile cross section & punching diagram
Profile 1
Profile 2
Ⅲ、 Process flow:
Uncoiling and leveling--->Servo punch punching--->Roll forming (hoisting module type)--->Laser welding--->Servo follow cutting device (band saw)--->Output table
Ⅳ、 Main parameters of the unit:
Unwinding and leveling machine:
1、Uncoiler: Passive unwinding, hydraulic tensioning
2、Uncoiler bearing capacity :3T
3、Unwinder coil inner diameter: φ508mm
4、Rolling range: φ470-530mm
5、Rolling width: 200mm
5、Uncoiler hydraulic system power: 1.5KW
6、Unwinder hydraulic system oil pump: gear pump or vane pump
7、Unwinder hydraulic system solenoid valve: Beijing Huade
8、Unwinder electrical control system: main electrical components adopt well-known brands
9、Inverter: Yaskawa (Japan)
10、Leveling structure: two rollers for pinching and seven rollers for leveling
11、Leveling roller diameter: about φ52.5mm
12、Leveling roller material: high quality 40Cr
13、Leveling shaft heat treatment method: surface high frequency quenching treatment
14、Motor power:3KW
2)Servo feeding & punching (punch press)
1、Feeder specification model: NC-200
2、Servo feeder power: 3KW
3、Servo motor brand: Delta or Innovance
4、Allowable material thickness: 2mm
5、Feed speed：≤30m/min。
6、Servo single step accuracy：≤±0.1mm（Within 200mm）≤±0.2mm（Within 500mm）
7、Punch model：JH21-110T
8、Rated pressure： 110T
9、Number of strokes: 35-80 times/minute
10、Main motor：11KW
11、Punching die：2 sets（Punching dies need to be replaced when producing different profiles）
12、Upper and lower mold material ：Cr12MOV
13、Upper and lower die heat treatment method: quenching HRC58-60
3）Molding host
1、Profile section: subject to confirmation by both parties
2、Applicable plate: 2mm
3、Molding machine structure: hoisting modular structure, cast iron arch gear box drive
4、Forming machine frame: high quality steel after welding vibration stress relief processing, CNC gantry milling processing each time has a arch positioning keyway, to ensure the parallel of the forming roller
5、Guide feed frame structure: lateral hand wheel type, guide roller quenching treatment. (When the left and right guides are set at the feed port of the main machine, the raw material sheet enters the main machine after being guided by the left and right guides, so that the raw material sheet and the roller forming system maintain the correct position; the guide position can be adjusted by the manual screw mechanism, and the left and right can be adjusted independently.
6、Hoisting molding module structure: 2 sets
7、Molding machine motor power: 15KW (K series gear reducer)
8、Forming number: Profile 1 (18 tracks) Profile 2 (18 tracks)
9、Forming speed: 0-15 meters/min (production speed is about 6-10m/min, the final production speed is determined by the laser welding speed during production)
10、Rolling material expansion width: based on the actual test plate width
11、Roller Material: 40Cr Quenching and tempering process（HB220-260）
12、Roller shaft diameter: Φ70
13、Roller processing method: CNC lathe processing, external cylindrical superfine grinding
14、Roller material: Cr12mov quenching treatment (HRC58-62)
15、Roller processing method: CNC machining to ensure circular runout and radial runout.
16、Spacer sleeve: In order to reduce the runout of each roller, the spacer sleeve adopts thick wall tube processing to ensure the shape and position tolerance, increase the contact surface with the roll, and the gap between the inner hole and the roller.
17、Length gauge： ±1mm
18、Straightening mechanism: Turkish correction head (can be adjusted up and down, left and right)
19. Protective device: Install a protective cover or protective net on the transmission side
4）Laser welding
Power：6000W
Control method: Industrial computer
Laser system: Fiber CW laser (Raycus)
Output center wavelength: 1070±10
Welding method: continuous
Laser welding: 0.2-5mm
Fiber length: 10m
Host size1.0*1.0*1.6m
Operating Voltage380V/32A
Operating temperature0-40℃
5）Cutting mechanism
1、Sawing mechanism structure: Servo tracking band saw cutting
2、Sawing mechanism base: High-quality carbon steel plate is treated with vibration or tempering to relieve stress after welding, and processed by CNC gantry processing center.
3、Sawing motor power: 11KW (K series gear reducer)
4、Fixture (tooling): Double-cylinder clamping design is adopted to ensure the stability of clamping and prevent the surface of the workpiece from being scratched.
5、Linear guides and ball screws: well-known domestic brands
6、Propulsion servo motor power：1.5KW
7、Tracking servo motor power：4.5KW
8、Servo motor brand: Xinjie
6)Support table
7)
1、Structure: Angle steel welding, roller dragging
2、Specifications: 1.5mx3 pieces
8）Electronic control system
1、Inverter: Xinjie
2、Computer uses PLC control: xinjie motion controller
3、Computer operation panel: MCGS (with protective shell)
4、Encoder: Koyo or Omron
5、Other electrical components: domestic well-known brands
Touch screen interface:
PLC control cabinet appearance：
Ⅴ、 Other instructions:
1. Trial Materials: The buyer is responsible for providing sufficient trial materials at least 20 days before shipment.
2. After-sales service: If used and maintained correctly, the factory warranty is 1 year. Losses caused by improper use and non-equipment failures are not covered by the warranty, and wearing parts (electrical components, etc.) are also not covered by the warranty. The warranty period starts from the date the equipment is provided.
3. Installation: If installation is required, Yanwu (the seller) will dispatch a technician to the buyer's factory. The buyer is responsible for the board and lodging of the seller's engineer. After the installation and commissioning of the entire set of equipment is completed, the supplier and the buyer must go through the acceptance and commissioning completion handover procedures. If the equipment is put into use without going through the handover procedures, it is deemed that both parties agree that it is qualified.
4. If overseas debugging is required, the purchaser shall be responsible for the supplier's engineer's visa application, air tickets, accommodation and related expenses, and provide a subsidy of USD 150/person/day, as well as the engineer's personal safety.
Flow diagram:
