Steel Silo Roll Forming Machine

Product Detail

Technical Proposal 


Name: curved corrugation automatic production line


Model:GWC 12-102-1122         

profile  

                  

picture 1 section of profile

proposal of production line

This production line realizes decoiling, roll-forming, punching, curving, cutting and stacking as an automatic producing process, requiring 1 worker.


(Modified)

Transmission of roll-former is chain wall plate

Curving is after roll-forming, then cutting. The curving machine can curve two-direction, the curving radius is adjusted manually.

The puncher has three punching station, it punches all holes one time together (we call this bulk puncher)

total power of this production line:

main roll-former:  15KW 

curving system: 2.5KW

hydraulic system: 11KW (including the motor power)

12*1.5*1.3

The dimension is 12m*1.5m*1.3m

technical process/sketch

decoil?guide&feed?level?roll-form? bulk punch?curve following roll-forming?hydraulic cut?stack

basic parameters of finished product 

Thickness of panel: 0.5-3.0mm hot-dip zinc-coated steel

Mechanical performance:yield strength 340MPa

tensile strength 470MPa

coil width: 1000mm-1200mm or as per customer request.

inner diameter of coil:f460-550mm 

The standard length of finished products: pls see the above drawing.

main configuration and technical proposal 

(pls refer picture 6)

passive decoiler 10T

/During normal processing, the decoiler works passively.

The capacity of this decoiler is around 10T, the width of coil is 1250mm.

Feed&level system: five-roller leveler.


(Pictures are based on specific profiles)

roll-former

The construction of roll-former: wall frame

Transmission way: motor-chain drive-chain -main shaft

as per drawing

Roll-forming station: 17 stations

15KW   415V   50HZ  3-?  ????(???? ABB)Brake Motor Model:ABB

Main power: 55KW   380V     50HZ  3-phase  brake motor

Main reducer: Cycloidal Pinwheel Reduction Box: 33-43-15KW.

Material of rollers: GCr15 high-carbon chromium bearing steel, the hardness after heat treatment: HRC58-62

The shape of rollers is designed through German design software COPRA, and processed on the precision NC machine. The surface of rollers is polished

The diameter of shaft for rollers: f120mm, 45# steel quenched and tempered.

The dimension of roll-former: around 12m(length)*1.5m(width)*1.3m(height)

hydraulic puncher

The hydraulic puncher consists of gantry(gantry consists of upper and down board, and post), punching die, hydraulic oil cylinder and etc. 

This puncher has three station, punches all holes together one time, each station has two oil cylinder, middle punch die has rack-and-pinion synchronizer

Demould way is combining polyurethane soft demould and hard press die together.

In order to install and exchange punching die easily, here we use construction in ball-lock style.(Modified and bases on the specific drawings)

              

up board of gantry   

post of gantry   

down board of gantry  

guide post&guide bush   

discharge board   

punch oil cylinder  

punch die(Modified and bases on the specific drawings)

curving machine

The construction is three-roller and horizontal type

This curving machine curves continuously following the roll-former, this can avoid the straight ends of panel, and besides, panel can be feed in and curved manually.

the minimum radius of curving arch is R2m, the radius can be adjusted.(Based on the specific drawings.)

hydraulic cutter for corrugation panel


This cutter consists of shear, angel adjustment system, system for adjusting higher or lower and backward or forward.

Cutting power: is provided by hydraulic oil cylinder.

Blades: the shape is matched with corrugation panel, the blade material is Cr12 die steel, hardness after quenched: HRC58-62.



hydraulic cylinder  

up and down blade  

manual worm and gear worm and gear reducer    

worm and gear reducer

cutter sketch(Modified and bases on the specific drawings)

stacker for finished products

Stacker consists of elevator device, device to move main carriage crosswise&longitudinal, stacking carriage, transmission device and etc.

The stacker can be moved crosswise manually, in order to stack at two station

Usual run-out and stack process will not interfere swinging finished products

When the height of stacked finished products has reached 200-300mm, the stacked products will be move aside to be packed and swinged, another station will continue stacking.

hydraulic system


hydraulic system for puncher:

main power: 55KW,  380V  50HZ    3-Phase 

power of cooling pump: 4KW,

system pressure: 25MPa, 

output volume of oil pump:63ML/R?

hydraulic system for decoiler:

main power : 7.5KW,    380V    50HZ   3-Phase

system pressure: 16MPa, 

output volume of oil pump:20ML/R.

computer control system

MITSUBISHI (PLC)

ABB frequency convertor

touch screen (HMI)(Modified)

Rotation encoder Omron brand±0.1mm positioning fiber

Main electric control elements is of brand Schneide and etc.

Two operation way: manually and automatically

safety and protect function:









During the manual or adjusting work way, the switch of operate board can give order to each part.


During the automatic work way, the switch of the operate board can not give order to any parts, only the emergency stop switch is valid.


Emergency stop buttons are set onto the both ends of production line, in order to emergently stop the machine when error happened, to insure the emergency brake of the system.

There is drive inverse function in a short distance.

technical parameter of corrugation panel

Tolerance of total length:±1mm

Tolerance of rib depth:± 0.8mm

Tolerance of hole location:=0.3mm

The arch of corrugation panel: can be adjusted, the minimum radius is 1.6m

Tolerance of arch of corrugation panel: ±5mm adjustable

The quality of corrugation panel appearance: the zinc surface should be kept well basically, during production, some zinc will stick onto the rollers, so workers should often clear the surface of rollers, to insure that there’s no obvious scratch on the roller surface.

Production speed:  1 piece of finished product per minute

Quotation

1.FOB shanghai price: USD93750/set

2.Payment Term: 30% down payment, 70% balance must be paid after on-site inspection.

3.Lead Time: 30 days after received the deposit.

4.Validity: the quotation will be valid for 30 days

5.Warranty: 12 months after shipped the machine and engineers available to service machinery overseas