Roll forming – FAY https://importfay.com/en/ Импорт аутсорсинг Thu, 15 Oct 2020 06:52:43 +0000 en-US hourly 1 https://wordpress.org/?v=5.7.12 https://importfay.com/wp-content/uploads/2020/09/cropped-cropped-fay_favicon_1-32x32-1-32x32.png Roll forming – FAY https://importfay.com/en/ 32 32 Equipment for the production of radiators https://importfay.com/en/product/equipment-for-the-production-of-radiators/ Thu, 10 Sep 2020 16:04:08 +0000 https://importfay.com/product/equipment-for-the-production-of-radiators/ Equipment package (plant) for the production of radiators.

Radiator width: up to 900mm. Plant capacity: 360-650 thousand pcs.

Сообщение Equipment for the production of radiators появились сначала на FAY.

]]>

APPLICATION

Equipment package for the production of radiators for heating systems. Product parameters and equipment performance are agreed in the terms of reference.

Typical specifications of radiators:

  • Power: 360-9.000W
  • Product size: 300, 400, 500, 600, 900mm
  •  Radiator length: 400-3,000mm
  • Types: 10,11.20,21, 22 (standard), 33

FEATURES

The equipment is automated and integrated into a single production chain – a radiator manufacturing plant.

The plant consists of the lines for:

  • Punching
  • Welding
  • Powder painting
  • Packaging

The lines contain all the necessary equipment for the production of 360-650 thousand units per year. Three-shift operation is planned. Radiator assembly and some technological operations are performed manually.

Additional equipment is used to increase the automation of assembly and packaging, as well as for increasing the line performance and applying highly durable paint.

PRODUCT LINE

Punching line

Manufacturing of the halves of the radiator cases, grilles, and brackets. The machines are automated and operated by a controller. The operating modes are set by the operator.

The line starts with the steel feed system. It consists of a hydraulically driven uncoiler and a device that feeds the steel sheet to the machine.

The equipment is characterized by high accuracy of sheet feeding (±0.01 mm).  The controller synchronizes the operation of the coil openers and pushers, as well as straightening and feeding devices.

A high-precision forming and cutting press is used for the production of case halves. The press machine operation modes and speed are controlled from the control panel with the controller. The control unit is equipped with the necessary switches and indicators.

The punching press is equipped with a tool with programmable dies. Various tooling is used to produce panel halves for the production of undulate radiators, grilles, end faces, and brackets.

The hydraulic system of the press is protected with a device that reduces the pressure in the cylinder in case of overload. The device protects the press from locking in the lower position when setting the die.

Line capacity:

  • 240m/h (700-900mm radiators)
  • 480 m/h (300-600mm radiators)

The line is equipped with an automatic lubrication system. A compact roller conveyor moves workpieces from the press machine to the welding line

Specification

  • Panel material: cold-rolled steel DC-01 (1.1-1.2mm)
  • Convector material: St12 steel (0.35-0.5mm)
  • Feeding unit capacity (t): 10
  • Maximum roll width (mm): 1,000
  • Steel thickness (mm): 0.4-1.5
  • Number of programs: 127
  • Length (mm): 0.05- 9999.99
  • Feed mechanism accuracy (mm): 0.05-9.9
  • Function selection: single stroke/automatic
  • Quick-change press die
  • Modem for teleservice
  • Counter of units and strokes
  • Diagnostics

Welding line

Линия сварки состоит из оборудования для двухрядной и продольной сварки панелей радиаторов.

Скорость и параметры сварки контролируются электроникой. Контроллеры имеют Ethernet интерфейс для управления через панель оператора и ПК.

Панели радиатора перемещаются по линии сварки с помощью сервоприводов.

Основные технологические узлы и операции сварочной линии:

Блок 1

  • Подача половин корпусов на входной рольганг
  • Центрирование половин корпусов и монтаж опорных колец
  • Поворот

Блок 2

  • Предварительное скрепление половин панелей
  • Двухрядная многоточечная сварка
  • Ручная загрузка конвекторов
  • Центрирование и позиционирование конвекторов
  • Двухрядная многоточечная сварка

Блок 3

  • Двойная продольная сварка модулей панелей
  • Продольная обрезки кромки (фрезерный станок)
  • Двойная поперечная сварка модулей панелей
  • Нарезка на панели

Блок 4

  • Обрезка кромки и пробивка отверстий

Блок 5

  • Поворот панелей на 180⁰
  • Монтаж радиаторов и приварка кронштейнов

Блок 6

  • Испытания на стенде (1-3 радиатора)

Dimensions of workpieces

Radiator length (mm) Quantity Workpiece length (mm)
400 4 panels 1,600
500 4 panels 2,000
600 4 panels 2,400
700 4 panels 2 800
800 – 1 000 3 panels 2 400 – 3 000
1 100 – 1 500 2 panels 2 200 – 3 000
1 600 – 3 000 1 panel 1 600 – 3 000

The minimum workpiece length is 1,600 mm (4x400mm, 1×1,600mm)

Number of welding points

Radiator height (mm) Panel Convector (without cutouts)
300 7 (with a shunt) 7 (with a shunt)
400 10 10
500 13 (with a shunt) 13 (with a shunt)
600 16 16
700 18 18
900 24 24

 

Powder coating line

The powder coating line consists of a chamber, a double conveyor, a pre-treatment and drying section. The coating paint line speed (2.5m/min) is coordinated with the welding section speed.

Radiator workpieces are pre-treated by immersing in a tank with a primer. Radiators are dried in a gas-heated chamber.

The polymerization chamber is made of stainless steel.  It has an axial cylinder and 6 automatic nozzles. There are a cyclone and filters for cleaning the gas medium. The curing oven is heated by gas.

The chamber conveyor has C-shaped hooks that ensure uniform coloring of products.

Main process steps on the line are:

  • Pre-treatment (priming)
  • Pre-drying
  • Immersion in an adhesion enhancer
  • Drying
  • Cooling
  • Automatic powder coating (epoxy-polyester, 60-100pm, sintering at 190°C)
  • Polymerization chamber
  • Cooling and unloading
  • Maximum product length (mm): 3,000
  • Maximum product width (mm): 300
  • Maximum product height (mm): 900
  • Maximum weight (kg): 200 – on 2 hooks
  • Average load (kg/m): 80
  • Average speed (m/min): 2×2.5
  • Paint drying time at 80-150°C (min): 17
  • Powder curing time 190-230°C (min): 28

Packing line

Packing of finished products in a protective film is partially automated and consists of the following process steps:

  • Semi-automatic unloading of radiators from the coating line conveyor.
  • Manual installation of the upper grid and side cover on the conveyor
  • Packing of the radiator in a box (manual)
  • Installation of protective edges (manual)
  • Wrapping in film and cutting the film (automatic)
  • Unloading of packaged radiators (manual)

OPTIONS

  • Magnetic gripper is a device for automatic loading of half cases on the welding line conveyor. It helps to reduce downtime and process interruptions
  • Plug installation device for installing the plastic plugs on all radiator connections.
  • Automatic suspension system on the coating line conveyor is a transport system before of the coating line that regulates the speed and height of hanging radiators. The operator hangs the hooks on a chain and inserts them into the holes in radiators
  • Electrophoretic coating equipment consists of a chamber and related equipment for coating radiators with a scratch and corrosion resistant paint (the technology is used for painting cars)

SELECTION

To select a line with the suitable capacity and products size, please, leave a request to our specialist

Сообщение Equipment for the production of radiators появились сначала на FAY.

]]> Roll forming machine (structural profile) https://importfay.com/en/product/roll-forming-machine-structural-profile/ Thu, 10 Sep 2020 15:32:11 +0000 https://importfay.com/product/roll-forming-machine-structural-profile/ Equipment for the production of structural metal profiles by cold-rolling.

The thickness of the processed steel is 0.5-4.0mm

Сообщение Roll forming machine (structural profile) появились сначала на FAY.

]]>

APPLICATION

Equipment for cold rolling of steel strips into structural profile (Light steel thin-walled structures). The metal profile is used for the construction of frames of prefabricated buildings.

The roll forming machine is used for the production of:

  • C, Z-profile (width 100-240mm)
  • Σ-profile (width 50-130mm)
  • Guide profile for drywall (0.5-0.6 mm)

The metal profile is made of strips of the required thickness. The profile geometry, along with the thickness and grade of steel, determines the load-bearing capacity of the structure.

C, Z, and Σ (sigma) steel profiles are used as columns and spans of walls and roofs of prefabricated buildings. The guide profile is used for the installation of drywall and structures for interior decoration.

The processed material is a steel strip or galvanized steel. The strip thickness is 0.5-4.0mm, the width is 50 to 240mm. Length of finished products is up to 12 m

FEATURES

The machine control system is fully automated and minimizes the human factor influence. The roll forming machine is controlled by a computer via a touch-screen graphical interface.
The tachometer monitors the unwound steel length and counts the produced profile length.
The shafts and passline rolls of the machine are manufactured on CNC machines with high precision.
Metal parts are made of structural steel with a chrome coating 0.05mm. The material of the shafts and rollers is wear and rust resistant. The guillotine blade is made of hardened steel and has a long service life.
The frame of the roll forming machine is annealed to prevent stresses and deformations during operation.
All roll forming machines are pre-tested before shipment. The equipment is guaranteed for 12 months.
We perform commissioning and provide technical support throughout the entire service life.

STRUCTURE AND OPERATION

The equipment pulls the steel strip from the roll and feeds it to the roll forming machine. The machine is a bending matrix equipped with rows of rollers on shafts driven by chain transmission.
The strip is profiled as a result of bending, where the strip is simultaneously exposed to compressive and tensile forces. Rows of rollers gradually form the strip into the desired profile, pressing the metal to the matrix.

1 Roll forming machine
2 Uncoiler
3 Control unit
4 Decoiler sensor
5 Roller conveyor 6 Main motor
7 Hydraulic drive
8 Guide table
9 Front cutter
10 Rear cutter 11 Oil tank
12 Water tank
13 Transmission drive

At the machine exit, the profiled sheet is cut off with hydraulic shears and fed to the output roller conveyor.
The rolling machine, electric and hydraulic drives, and chain transmission are assembled on a single frame. The uncoiler is a separate machine equipped with a sheet speed sensor.

PRODUCT LINE

FY-500Z

C-profile

  • Metal thickness: 1.6-3.2mm
  • Speed: 12-20m/min
  • Shaft diameter: 60mm
  • Number of rows: 13
  • Motor power: 15-20HP
  • Product dimensions: 75x45x15,100x50x20,125×5-X20

FY-500Z

Z-profile

  • Metal thickness: 1.6-4.0mm
  • Speed: 12-20m/min
  • Shaft diameter: 60mm
  • Number of rows: 16
  • Motor power: 20-30HP
  • Product dimensions: 150х50х20, 150х65х20, 50х75х20

FY-500CT

U-profile

  • Metal thickness: 1.0-1.2mm
  • Speed: 12-15m/min
  • Shaft diameter: 60mm
  • Number of rows: 10-12
  • Motor power: 20HP
  • FY-100S

FY-100S

Dry wall mounting profile

  • Metal thickness: 0.5-0.7mm
  • Speed: 12-16m/min
  • Shaft diameter: 45mm
  • Number of rows: 15
  • Motor power: 7.5HP

OPTIONS

The equipment contains all units necessary for sheet metal bending.  Additionally, the roll forming machine is equipped with mechanisms that form the production line:

  • Decoiler
  • Guillotine (electromechanical/hydraulic)
  • Mechanisms for conveying finished products (roller conveyor)
  • Packaging and marking equipment

SELECTION

To select the machine suitable for the production of the required profile, please, leave a request to our specialist. Attach product drawings to the request and specify the required performance.

Сообщение Roll forming machine (structural profile) появились сначала на FAY.

]]> Roll forming machine (profiled sheet, metal tile) https://importfay.com/en/product/roll-forming-machine-profiled-sheet-metal-tile/ Thu, 10 Sep 2020 15:25:00 +0000 https://importfay.com/product/roll-forming-machine-profiled-sheet-metal-tile/ Equipment for the production of profiled sheet metal by cold-rolling.

Profiled sheets are used for roofing, walls, sandwich panels. Standard profiled sheet width: up to 1,250mm

Сообщение Roll forming machine (profiled sheet, metal tile) появились сначала на FAY.

]]>

APPLICATION

Equipment for cold rolling of sheet metal into profiled products.

Profiled sheets are used in construction for enclosing structures (roofs, walls, doors, thermal insulation panels) and shaped elements. The metal profile is used for spanning buildings and structures. The product is used in prefabricated construction.

The roll forming machine is used for the production of:

  • Metal tile
  • Roofing sheets
  • Profile sheets
  • Corrugated sheets

The metal profile is made with the required rigidity and strength. Using a type of profile with a suitable cross-section helps to save on supporting structures and reduces metal consumption. The sheet has the necessary spaces for easy installation.

The material is 0.2-0.8mm steel. Standard width of sheets: 1000/1200/1220/1250mm. Product length: up to 12m. Galvanized or painted sheets are available.

FEATURES

The machine control system is fully automated and minimizes the human factor influence. The roll forming machine is controlled by a computer via a touch-screen graphical interface.

The tachometer monitors the unwound steel length and counts the produced profile length.

The shafts and passline rolls of the machine are manufactured on CNC machines with high precision.

Metal parts are made of structural steel with a chrome coating 0.05mm. The material of the shafts and rollers is wear and rust resistant. The guillotine blade is made of hardened steel and has a long service life.

The frame of the roll forming machine is annealed to prevent stresses and deformations during operation.

All roll forming machines are pre-tested before shipment. The equipment is guaranteed for 12 months.

We perform commissioning and provide technical support throughout the entire service life.

STRUCTURE AND OPERATION

The equipment pulls the steel sheet from the roll and feeds the web to the roll forming machine. The machine is a bending matrix equipped with rows of rollers on shafts driven by chain transmission.

The sheet is profiled as a result of bending, where the sheet is simultaneously exposed to compressive and tensile forces. Rows of rollers gradually form the sheet into the desired profile, pressing the metal to the matrix.

1 Roll forming machine
2 Uncoiler
3 Control unit
4 Decoiler sensor
5 Roller conveyor
6 Main motor
7 Hydraulic drive
8 Guide table
9 Front cutter
10 Rear cutter 11 Oil tank
12 Water tank
13 Transmission drive

At the machine exit, the profiled sheet is cut off with hydraulic shears and fed to the roller conveyor.
The rolling machine, electric and hydraulic drives, and chain transmission are assembled on a single frame. The uncoiler is a separate machine equipped with a sheet speed sensor.

OPTIONS

The equipment contains all units necessary for sheet metal bending.  Additionally, the roll forming machine is equipped with mechanisms that form the production line:

  • Decoiler
  • Guillotine (electromechanical/hydraulic)
  • Mechanisms for conveying finished products (roller conveyor)
  • Packaging and marking equipment

SELECTION

To select the equipment suitable for the production of the required metal sheet please, leave a request to our specialist. Attach product drawings to the request and specify the required performance.

Сообщение Roll forming machine (profiled sheet, metal tile) появились сначала на FAY.

]]>