Cable Tray Roll Forming Machine

Passive Decoiler ----- Flattener ------ Front Material Store ----- Intermission Feeder ---- Punching ---- Rear Material Store ----- Guiding ----- Roll Forming ------ Profile Rectifying- ---- Measure and Cut ----- Runout Table

Description:

(1)Load coils onto the double head decoiler's expansion system.

(2)Start the equipments and feed the material into the flattener manually.

(3)The material after flattened is accurately fed into the mechanical puncher for ordinal punching. The accumulated tolerance of the central distance of holes is subject to the feeding system.

(4)The front and rear material stores are used to adjust the non synchronization caused by the discontinuous moving in punching.

(5)The material after flattened and punched is rolled through the specially designed tooling station by station to form the required shape.

(6)At the end of the roll former a rectifying system is mounted to rectify the shape and straightness of the formed product to the final profile.

(7)The hydraulic cutter controlled by photoelectric switch and measuring system is used to cut the finished material into required length.

(8)The finished products, counted by the PLC automatically, are conveyed to the simple run out table where the workers can take them for package or to the warehouse.

Main Configuration and Technical Details
The line is mainly consist of one double head decoiler, one flattener, one front material store, one serve feeder, one mechanical puncher, one roll former, one rectifying system, one cutting system, one hydraulic system, one electrical controlling system and one run out table, etc.

1. Double Head Decoiler

This decoiler with a steel welded structure, decoiling passively, adopts coils with ID of φ500mm. It is operated manually under which it can load coils on both the heads which can be circum gyrated.

2. Flattener

According to the flatness accuracy requirement, the flattener, calculating under the theory of minimum distortion is used to flatten, convey and draught the material. The flattener has 5 flattening rollers, 2 feeding rollers and 2 delivering rollers. And the distance of the rollers can be adjusted according to the thickness and rigidness of the material to ensure an ideal flattening function. The flattening rollers are made of heat treated high alloy steel to ensure the rigidity and abrasion proofed characteristics.

3. Front and Rear Material Stores

In order to match the speed of intermission feeding while punching and the continuous feeding while roll forming for continuous production, in front and rear of the puncher material stores are supplied, in which the length of the material naturally sinks is able to provide a cushion for the interval of punching and the continuing of the roll forming. The dimension of the material stores depends on the forming speed. Photoelectric sensor equipment, mounted in the material stores, can stop or re start the roll former when the accumulated material monitored is too long or less.

4. Intermission Feeder

This system, adopting sever roller feeder and computer controlling panel on which by input the feeding length the required feeding distance can be reached, is to feed the material into punching area in high accuracy.

5. Mechanical Puncher

The puncher, adopting JF21-63 pressing system, combination pneumatic friction clutch, pressing brake and vertical axes, has an advantage of good rigidity, high accuracy, smooth clutching, flexible moving and low noise.

6. Roll Former

The roll former is designed to have 20 forming stations sitting on steel structured frame. Every station is driven by gear box through universal shaft. The material is rolled through the roll former station by station to form the shape gradually by the rollers of GCr15 bearing steel, which were designed in Germany Roller Designing Software COPRA, processed on CNC lathes and heat treated at

7. Rectifying System

8. Hydraulic Cutting System

9. Hydraulic System

10. Electrical Controlling System

11. Material Automatic Controlling System