Special Design for Cable Tray Forming Machine - Highway Guardrail Roll Forming Machine – Xinnuo

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what is metal roll forming?

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Special Design for Cable Tray Forming Machine - Highway Guardrail Roll Forming Machine – Xinnuo Detail:

*Detail

Xinnuo highway guardrail roll forming machine is comprised of roll former unit, press. decoiler, receiving rack, and computer control system. It is designed especially to produce highway guard rail, which works to transfer the impact energy through the deformation of column and beam, to force the out-of-control vehicle to go back to its original direction, and to protect the vehicles and passengers to the max extent.

*Working Process：

Uncoiler—Levelling and Feeding—Punching—Encoder sizing Cutting—Main Forming Machine—Unloading Device—PLC Control System
Equipment main component technology parameter：

Uncoiler

Double-cone power drive boost and clamp uncoiler. Load capacity is 5 tons. Motor power is 2.2kw, cycloidal pin gear speed reducer, speed ratio is 35; Coil inner diameter range is 450mm-600mm, effective coil outer diameter is 1600mm, Uncoiler with feeding brake mechanism.

Levelling and Feeding

Wallboard type 7 rollers levelling machine, 2 rollers feeding and 5 rollers levelling, wallboard thickness is 50mm, levelling roller diameter is 119mm, roller material is 40Cr, heat treatment HRC48º～52º. Levelling machine front and back equip guiding vertical rollers, feeding part equip guiding device. Motor power is 11kw, frequency control, ZQ350 reducer, speed ratio(i=20.49), levelling speed is 1-18m/min, levelling width range is 300-500mm, equip clutch device.

Punching and Encoder sizing cutting

Equipment adopts four-column type, Hydraulic motor power is 22kw, equip one set of punching mould, can choose the hole type according to requirement. Encoder sizing accuracy is 3200±2.0mm; punching length can modify on PLC according to need, and meet manufacture requirement.

Main roll forming machine

Main roll forming machine have 12 roller stations, independent opening standing Cassette type structure, machine expansion width is 550mm. Machine equip 3 sets of guiding vertical rollers. Roller diameter is φ80, roller material is 40Cr, thermal treatment. Single shaft down driving gear box 10 set in total, bevel gear modulus M=9. Main machine power is 37kw, frequency control, with ZQ650 reducer, speed ratio is 48.57, assemble five models. It adopts 1.2 inch double row chain driving between each gear box; adopts chain wheel and chain to connect the gear box and shaft, Main roll forming machine speed is about 15m/min. Two-wave guardrail forming rollers one set, roller material is GCr15, integral quenching, hardness HRC58～62º.

Unloading device

Unloading device roller type, length 6M, weld with 8# groove steel, equip rollers slide.
Control System

Adopt PLC control, Manual and automatic control of all parts of the assembly line, control cabinet equip 7 inch touch screen, can adjust and change the setting parameter according to manufacture requirement, The electric control operator is equipped with the starting, stopping, transforming and adjusting of the components, and equipped with the equipment trouble stop button.

Other

Equipment use anti-rust treatment first, then coated with steel structure specialized anti-rust painting, which covers the entire surface, after that coat the equipment with high quality finish paint, color is blue and green. Transmission part uses warning color to distinguish.

*Detail Pictures

*Application

Product detail pictures:

Advantages of Roll Forming A Metal Part

There are several advantages of using roll forming for your projects:

The roll forming process allows operations such as punching, notching, and welding to be performed in-line. Labor cost and time for secondary operations are reduced or eliminated, reducing part costs.
Roll form tooling allows for a high degree of flexibility. A single set of roll form tools will make almost any length of the same cross-section. Multiple sets of tools for varying length parts are not required.
It can provide better dimensional control than other competing metal forming processes.
Repeatability is inherent in the process, allowing easier assembly of roll formed parts into your finished product, and minimizing problems due to “standard” tolerance build up.

Roll forming is typically a higher speed process.
Roll forming offers customers a superior surface finish. This makes roll forming an excellent option for decorative stainless steel parts or for parts requiring a finish such as anodizing or powder coating. Also, texture or pattern can be rolled into the surface during forming.
Roll forming utilizes material more efficiently than other competing processes.
Roll formed shapes can be developed with thinner walls than competing processes

Roll forming is a continuous process which converts sheet metal into an engineered shape using consecutive sets of mated rolls, each of which makes only incremental changes in the form. The sum of these small changes in form is a complex profile.

Automatic Forming Machine