The Components of a Rack Upright Roll Forming Machine
A roll forming machine bends metal at room temperature by rolling it through a series of stations where fixed rollers guide the strip and make the necessary bends.
This is a versatile method of creating precise, uniform parts. But the process can also lead to problems if not properly maintained.
1. Servo Feeder
The Servo Feeder, while not the first thing that comes to mind, is a must have in your industrial arsenal. It’s a slick piece of kit that can handle the gamut from heavy duty to light weight. Having one will save you time and money in the long run. It has all the high tech features and none of the high maintenance that comes with them. There are so many options to choose from that it can be a difficult task to narrow down the best one for you and your business. Luckily for you, we’ve made it our mission to bring you the highest quality industrial products and solutions at the lowest possible prices. Contact us for a custom quote today! You’ll be glad you did. The best part is you’ll be able to take a tour of our state of the art facility without paying a fortune! Just let us know if you have any questions or if you’d like to discuss a custom industrial roll forming solution for your business needs.
2. Hydraulic Punching Device
The Hydraulic Punching Device is one of the key components of a rack upright roll forming machine. It is used for producing storage shelf columns of different sizes and thicknesses based on the design and style required by the customer. The production process consists of Uncoiling-Punching Holes and Slots- Feeding and Guiding-Roll Forming-Cutting Off-Collecting.
In order to reduce the knocks and shocks induced by the punch going through the parts to be punched, a control hydraulic fluid penetrating into the piston chamber is applied on a permanent basis in addition to the driving hydraulic fluid. The damping pressure fluid penetrates into said chamber, containing the lower part of the piston, through a small section opening. This causes a pressure loss between the upper face of the piston and the lower face of the piston, thus balancing the elastic energy of the driving hydraulic fluid at the time it is being applied throughout punching.
During the downward motion of the piston, pressed by the under pressure liquid that feeds the chamber 4, linchpin 21 is pushed on the edge 23 of the separating unit which presses Pharmaceutical Packaging Machine on the part to be punched. At the end of a certain stroke, the application of the driving fluid ceases and the piston is reset under the influence of the damping hydraulic fluid pressure and of spring 24 which tends to bring back the punch upwards by pressing on the separating unit, which thus maintains the plate into place during extraction of the punch.
The damping pressure fluid then continues to be pumped through the valve 25 to the oleo-pneumatic accumulator 26 under pressure of 700 p.s.i. The pump 27 is operated by a three-way and two-position distributor 28 that is controlled by microcontact 15 and 16.
After a few minutes, the pressure in the lower chamber of the piston decreases. At the same time, the accumulated force in the separating unit increases and tends to press on the part to be punched. At this point, the linchpin 22 and the edge 23 of the separating unit are pulled away from the part to be punched, and the spring 24 begins to compress.
3. Main Roll Forming Machine
A rack upright roll forming machine is a specialized piece of equipment that produces a wide range of storage racks. These racks are made from galvanized steel and are used for warehouse pallet racking systems. These products are incredibly popular across many industries because of their dimensional accuracy, durability and high-quality.
The forming process involves using rolls that progressively change the shape of sheet metal as it is passed through the machine. Each set of rollers bends the metal slightly more than the last, creating a complex cross-section profile.
These profiles can be very different, so the tooling for the rolls must be crafted very carefully. Often, these roll tools are designed using CAD or computer-aided design (CAM) renderings to ensure that all of the contours will be formed properly and that the resulting product is able to meet all of the specifications.
Once the profile is ready, it can be cut to length by the machine. This is done with either post-cut or pre-cut shears, depending on the needs of the client.
In addition to cutting the length of the piece, a roll forming machine can also offer a number of other services. For example, it may be able Pharmaceutical Packaging Machine to add applications such as slots or holes for additional functionality.
Another service a roll forming machine can offer is straightening, which is useful when the finished products have bow, camber, or twist that requires straightening. This is done by removing the tension in the metal that has been induced by the previous forming processes.
It is important to note that when these straightening procedures are performed, the metal must be heated. This can cause the material to change its shape, so it is a good idea to choose a temperature that will keep the metal at a consistent level and avoid changing the shape.
The servo feeding, hydraulic punching device and main forming mill of this rack upright roll forming machine are all controlled by a PLC. These specialized computers are designed to continually monitor the machine and make adjustments. This allows the manufacturer to create parts that meet all of the necessary dimensional specifications while being produced in the most efficient manner possible.
4. Hydraulic Shear Unit
The Hydraulic Shear Unit of a rack upright roll forming machine can cut and separate the steel sheet of various thicknesses by applying a shear force. It can also be used to make a variety of welded steel products such as doors and windows, refrigerators, and electric cabinets. It is widely used in the fields of decoration, electrical appliances, electric power, automobiles, ships and aerospace.
The shearing process of a hydraulic shear machine is based on the principle that the upper blade on the blade carrier and the lower blade fixed on the blade holders adopt reasonable blade clearance to apply shearing force to the metal plate. The shearing force is induced by the pressure of the hydraulic system, which drives the up and down movement of the upper blade and the fixed lower blade.
During the shearing process, it is important to control the gap between the upper and lower blades and the thickness of the sheared metal sheet, so as to ensure the cutting accuracy and protect the cutting edge of the shearing blade. Generally, the gap is about 10% of the thickness of the sheared material.
It is very easy to hurt the operator if the upper and lower blades dislocate, which can be easily caused by incorrect operation or improper maintenance. The gap should be adjusted according to the requirements of the shearing workpiece.
In order to achieve the best shearing effect, it is necessary to pay close attention to the blade gap, the lubrication, and the working condition of the shearing machine. In addition, it is necessary to check the valves, tubing and connectors.
If the shearing process is not properly performed, the result will be poor quality and high waste production. In order to avoid this, it is recommended that the shearing operation be performed twice a week, and the machine is inspected and serviced regularly.
National’s NH9625 is an excellent hydraulic shearing machine for cutting mild steel, aluminum, plastic, copper, brass and a wide range of composite materials. The 96 inch x 1/4 inch capacity model features spring actuated hold downs, front sheet supports, a manual back gauge with positive locks and a reversible 4-ft. squaring arm with embedded scale. It is backed by a five year warranty and lifetime breakage protection on the shearing table.