Autocar Carriage Plate Roll Forming Machine
|FOB Price:||US $300,000 / Set|
|Min. Order:||1 Set|
|Min. Order||FOB Price|
|1 Set||US $300,000/ Set|
|Production Capacity:||2~3 Sets/Year|
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- Model NO.: BU
- Forging Forming Method: Free Forging
- Feature: Automation
- Warranty: 12 Months
- Advantage: Easy to Maintenance
- Steel Forming: Cold Rolled
- Transport Package: Complete Shipping Package
- Origin: Shandong Jinan
- Type: Auto Sections Roll Forming
- Power Source: Electric
- Certification: CCC, SGS, ISO9001, CE
- Customized: Customized
- Condition: New
- Trademark: BU
- Specification: CE, ISO9001: 200
- HS Code: 8455221000
The autocar production line includes decoiler, uncoiler car, leveler, rotary holding frame, feeding guide, main roll forming machine, flying cutter, automatic stacker and PLC control system.
Whole line the working speed is much high, and the puter form is bright and pretty, automatic level is much high and the operation is very convenient.
Deatiled information for forming line (reference version):
(1) Coil Width: free data (according to future profile requirements)
(2) Suitable Coil Thickness: 1.0~3.0mm
(3) Suitable Raw Materials: cold rolled steel/hot rolled steel
(4) Raw material kind: S350, S550, DP780, DP980, DP1180
(5) suitable steel coil inner diameter: ¢508mm
(6) suitable steel coil outer diameter: ≤¢1800mm
(7) Suitable steel coil max weight: 5 Tons
(8) Roll forming line power source: 380V/50HZ/3 Phase
(9) Roll forming line speed: ≤5m/min
Ø ROLL FORMING LINE WORKING PROCESS:
Decoiler→leveler→coil head/end part cutter and welder device→servo feeder→multi-station punch system→main roll former→straightener→flying shear→final products rack
Ø MACHINE COMPONENTS:
|1||Single head hydraulic decoiler||Share with all profiles||1 set||It includes assist arm|
|3||Coil head/end part cutter and welder||1set|
|4||Servo feeder||1 set|
|5||Multi-station puncher system||C profile: |
working station 1#--R8.5×50
working station 1#--¢17
working station 2#--¢13
working station 7#--tip part cut
working station 8#-- tip part cut
|1 set||Punch system total has 8 working stations, similar like sent video show|
|6||Main roll former||2 sets "fast change cassette", in order to satisfy 2 profile forming requirements||1 set||One set cassette is only used to produce 1 profile|
|7||Flying shear||Cut final profile according with required length data||1 set||Continuous working model|
|8||Hydraulic system||2 sets|
|9||Pneumatic system||1 set|
|10||Electrical control system||1 set|
|11||Safety protection system||1 set|
Ø LINE TECHNICAL SPECIFICATION OF EACH PART
(1) Single head hydraulic decoiler (5 tons):
Automatic model; motor power drives decoiler shafts to opens steel coil, and hydraulic power expands steel coil inner surface, the expanding structure is "wedge type". in order to make steel coil to be fixed well on decoiler shaft. Decoiler also includes an assist arm and pneumatic power brake device. The assistant arm is used to support the decoiler shaft on working condition, it protect the decoiler shaft loading actions.
The decoiler is single heads model, max loading capacity: 5000kg
Suitable steel coil inner-diameter: ¢508mm, max outer diameter: ¢1200mm
This decoiler also includes a press arm device, when steel coil head or end part out of decoiler shaft, the press arm will push down and make steel coil head or end part to be out of decoiler shaft smoothly.
Decoiler also matches with decoiler car, when the steel coil needs to be load decoiler shaft, coil car will load coil at the first, and then sends coil under decoiler shaft, finally the coil car lifts up and make decoiler shaft load steel coil well.
Max load capacity of coil car: 5 tons
Decoiler drive motor power: about 5.5Kw
Coil car drive motor power: about 1.1Kw
(2) Leveler machine:
Leveler machine is used to level the raw material steel sheet, and make steel oil to be flat and satisfy main roll former requirements. When steel coil gat into leveler, raw material support table will move out and protect roller will push down, and then the steel coil head can get into the first leveler roller station smoothly.
Leveler machine includes power pinch roller and leveler roller, pinch roller can be adjusted on vertical direction, and it is convenient to adjust leveler roller space and incidence.
Leveler is 7 rollers model, the adjustment model is lead screw style, and one set guider device is installed at the leveler entrance.
Main data of leveler:
Suitable coil width: max 800mm
Suitable coil thickness: 1.0~3.0mm
Max working speed: 10m/min
Leveler roller material: GCr15 (heat treatment, HRC56~60)
Motor power: about 11Kw
The leveler machine satisfies 1300Mpa raw material yield strength!!
(3) Coil head/end part cutter and welder:
When steel coil head or end part get into this device, in order to make steel coil head/end part to be flat, cutter will cut the head and end part, and then welder will make old coil end and new coil head to be connected together.
The welder is automatic weld model, welder style is TIG.
Max weld width: 800mm
Weld thickness range: 1.0~3.0mm
(4) Servo feeding device:
Machine uses feeding shafts model, and this machine includes servo motor, a pair of feeding shaft, transmission device, guider and numerical control system. (Servo motor, measure accessories and numerical control system are all used import products.)
Servo motor power: about 5.5Kw
Servo motor brand: SIEMENS
Max working speed: 40m/min
Feeding roller material: GCr15 (heat treatment, HRC56~60)
The feeding length can be set freely, and operator can input 20 groups different feeding length.
The feeding speed can be adjusted freely, and each feeding length tolerance is ±0.15mm, and tolerance is not accumulation.
(5) Multi-station Puncher:
It is used to punch related holes on the section surface.
Puncher will use YANGLI brand products, and model is JH21 High performance of punch machine, main motor uses SIEMENS brand products, and matches with Hydraulic overload protection device, working flat is "six face+long rail" model, in order to keep working action to be stable.
Punch die is high speed model, when hole standard is changed, operator just needs to adjust punch die space, punch hole location will be changed soon. It is convenient to punch different kind of holes at same punch system.
Punch station uses air fork device, all punch station can be choosed and adjusted by PLC control system.
Punch speed: 35times/min
Punch die material: DC53 (heat treatment, HRC58~62, import material)
The holes distance which is on horizontal direction can be adjusted accord to requirements.
Puncher includes a complete set punch die, in order to satisfy C and Z profile punch requirements.
(6) Main roll former:
Main roll former uses single forming stand model, welded steel base plate.
Main roll former also includes a straighter. It is used to make final products to be straight.
Main roll former forming part is "fast change cassette" model, when profile is changed on roll former, operator just changes the forming cassette, it will be ok, the change time is short, and so the working efficiency will be increased. Not only main roll former is suitable for C and Z profile, but also it is suitable for "bumper" profile roll forming requirements.
Fast change cassette working principle show:
The transmission system includes main motor, decelerator, gear box, transmission shaft and etc. some up layer forming shaft are power, and the others down forming shaft are power.
Some necessary forming stands also use in-phase gear, in order to make forming process to be precise.
The roller is designed by professional software, and all rollers dimension are precise.
Roll forming stand number: C→16 stands
THE COMPLETE ROLL FOMRING MACHINE BASE CAN INSTALL 26 FORMING STANDS; IT CAN SATISFY FUTURE PROFILES FORMING REQUIREMENTS.
Max feeding steel coil width of main roll forming part: 800mm
Up layer forming shaft can be adjusted and adjustment method is lead screw style; down layer forming shaft is fixed. When up layer forming shaft needs to be adjusted, operator only uses one nut to adjust space which is between the up and down forming shaft.
Max feeding width of new profile forming stand: 800mm
Forming roller material: D2
(Import from USA, heat treatment and HRC58~62, roller surface is polishing treatment.)
Forming shaft material: 40Cr
Forming shaft dimension: different profile will use different shaft diameter
Forming stand material: QT470
Main roll former working speed: max 5m/min
Main motor power: about 55Kw×2
Main motor brand: SIEMENS
Note: main roll former includes a straightener (Turkey head), it is used to straighten final profile and make final profile keep suitable straightness.
(7) Flying Cutter:
The cutter model is flying cut and it is continuous cut style. Cutter die outer frame and base can be changed fast; the change style is similar as main roll former "fast change cassette", so the change time is short when profile is changed from one to another.
Cutter is driven by hydraulic power.
There is no waste piece after cut actions.
Cutter tool material: Cr12MoV (heat treatment, HRC58~62)
Cut length tolerance: ±1.5mm
Cut pressure: about 500KN
Cutter working efficiency: 2~5 times/min
The cutter can be cutted the final products on confirmed length, and the length is automatically fixed by coder. It can cut 12 metes length final product.
(8) Hydraulic system:
It supplies the power for the hydraulic decoiler and cutter.
Main components of hydraulic system are motor, oil pump, filter, pressure meter and hydraulic valve.
Electromagnetic valve uses Italy "ATOS" brand products, and pressure is about 0~20Mpa.
All hydraulic oil cleanliness should keep grade 6~8.
Hydraulic motor power: about 18.5Kw (use for flying cutter)
About 7.5Kw (use for hydraulic decoiler)
Motor brand: SIEMENS
(9) Pneumatic system:
System pressure: 0.7Mpa
All pneumatic accessories use Japanese "SMC" brand products.
(10) PLC Control System:
This system uses SIEMENS PLC to control all working actions. Production quantity and each piece length will be automatically measured; human and machine interface, touch screen is input and cancelled the working data. It is convenient to control the roll forming machine.
The control panel has English operation interface, it is convenient to input and cancel working date.
Main accessories show:
PLC: SIEMENS (Germany products)
Inverter: SIEMENS (Germany products)
DC controller: SIEMENS (Germany products)
Touch screen: SIEMENS (Germany products)
Control panel outer form reference picture:
(11) Product Rack (un-powered):
Two parts, each part length is 3 meters. The total length is 6 meters.
In order to collect the final product and final products is convenient to be stacked by workers.
This rack can be disassembled easily, in order to satisfy different working condition requirements.
(12) Safety protection system:
All safety parts, electrical accessories and key part driver all have CE certificate.
Moving parts will be installed protective cover.
Outer side the complete line, it will be matched with protective net and Safety light curtain. All roll forming line parts will be covered by protective net, totally it has 4 doors. Door will match with Safety check function; this system will use "Rockwell" system.