ZhongTuo High Speed Highway Guardrail Roll Forming Machine for W-Beam Production Customizable

Highway Guardrail Roll Forming Machine

Highway guardrail is  a continuous structure with corrugated steel guardrail plates spliced and supported by main columns. When the vehicle collides with it, it absorbs energy, which is not easy to be crashed, but also plays a good role in protecting the vehicle and drivers and passengers.

We will introduce one machine which can manufacture typical gurard W beam by roll forming process.

The profile drawing as below.

Material: galvanized steel, cold rolled steel, and carbon steel.

Thinckness: 2.5-3.5mm

 

Layout of machine

(only for reference, the exactly one will be send to customer in 20 days after confirmed order)Working direction base on customer request:

Decoiling----Feeding (take the sheet to the first station) ---leveling--- punching ---punching ---roll forming---cutting--run-out table

1. 5 ton hydraulic de-coiler

Coil holder: hydraulic mechanism for securing the coiled steel in the device, suitable for the required coil weight;

Steel coil width: 485mm;

Internal diameter of coil: variable, from 470 mm to 510 mm

Maximum coil weight: 5000 Kg;

Main motor power: 5.5KW AC motor

Hydraulic power: 4kw

Speed controlled by frequency converter

2: Feeding→leveling→punching→roll forming →post cutting

Ø Feeding and leveling

Main features of the machine:The leveling roller's mechanical property such as rigidity and roughness concentration of the surface are rising very much after hardening and tempering. It includes pinch roll and leveling roll. The pinch roll can adjust along. The leveling roll uses the whole structure. There are two adjusting point at the front and at the end. It can form a certain banked angle to improve the leveling quality. The feeding port of the leveling machine has a pair of guide plain-barrelled roll and two pairs of guide vertical roll. The guide vertical roll can moves centered or moves at the same time. It is adjusted by hand wheel, so it is convenient to centered

• Feeding the sheet to the guide roller (it is adjustable by right and left).
• Feeding roller: diameter is 160 mm, material is 40Cr steel, HRC48-52.°
• Leveling roller: upper is 4 rollers, down is 5 rollers (total is 9 stations), material is 40Cr steel, HRC48-52°
• diameter of leveling roller: 76 mm
• Sample photo for reference

Ø Punching

Using hydraulic punching, pre-punching

Oil cylinder diameter: 180 mm

Working pressure: 30MPa

Mould material: Cr12,  quenched 58°-62°

Hydraulic power: 22kw

Punching station: 2 stations

The base should be with scrap hole

Punching is control by PLC, punching the two waves profile and three waves profile, just need control the PLC. Not need change or adjust anything.

Ø Forming Machine

Machine frame: 400H steel

Main motor power: 30kw

Station: adopt guide pillar stations

Decelerating motor: 30KW, made in Shanghai or Changzhou

Transmission: by gear box: 200*500(outside is cast iron, surface needed polish and paint. Inside is 60# forge and press metal)

Main shaft dia: 90mm   material: 45# forge steel

Roller material: GCR15 quenched 58°-62°, black oxide coating

Roll station: 15 stations

Timing by transducer: 5m--12m/min(not including punching)

Transducer: Panasonic made in Japan. 415V 50HZ 3P

 Post cutting system

Profile transversal cutting device units allowing to cut the bent profile without damaging the metal coating and to assure a smooth cut: included;

Feeding of the last cut profile from the equipment: automatic if the length of the last profile is not less than 1500 mm;

Cutting after forming: Cut the sheet after roll forming to required length

Uses three hydraulic cylinders for operation shall include a flow regulator to achieve a uniform lowering knife.

Material of blade:Cr12, 58-62 HRC hardness

Cutting power by hydraulic, 11KW

Working pressure: 30Mpa adjustable

Length measuring: Automatic encoder length measuring, brand: Omron

The cutting sequence is also contained and controlled by the same PLC program

Tolerance of length: +/- 1.5mm for each piece end product

Ø Control Panel (Siemens)

Full line is controlled by PLC control system, touch screen operation to achieve the human and PLC interactive. The operator can monitor the setting program (programmable control) and modify the parameter to control the line. Also can check the running status, parameter and error indication etc.

Operation type: manual /auto two type switch. In manual position: can run the each part of the machine. In auto position: can run the full line. The emergency stop ensures the safe of the equipment and operator.

Machine side is equipped with the manual operation control panel for convenient worker to operate.

Entire line surveillance function: to reach surveillance production line movement condition, realizes to various locations production condition surveillance.

Has the failure detection function: Carries on to the production line signal succession examines, the checkup according to sequence, discovers the mistake, and giving the alarm to stop the machine.

Two language: Chinese and English, or as request

PLC brand: Siemens

Frequency converter brand:Siemens

Touch screen: Taiwan Weinview

1:Connections and safety

Electrical supply characteristics for all equipment units and control unit: will be declared;

Safety switches and emergency alarm: will be provided;

Other required connections: will be declared;

2. Materials and equipment

Lubricants: will be provided before the commissioning of the equipment, the specification, type of feeding, and the consumption will be declared in operation manual.

Liquid for hydraulic pressure stations: will be provide by testing in supplier factory, the specification will be provided in operation manual.

3.Installation of equipment for production of trapezoidal support profiles

Management of installation and assembly works of equipment (except for external connections): will be provided by the supplier;

Tools and materials for installation of the equipment (such as welding devices, wrenches, jacks, screws, etc.): shall be provided by the customer in accordance with written specifications provided by the supplier;

 Due to the spreading of Covid-19 all over the world, Zhongtuo is not able to send our team to install the machines at site. We will do below steps to help customer to install and commission the machines easily.

Zhongtuo will send the layout, manual, maintaining introduction, power required of the machine before machine shipment.

All the machines will be full tested in our factory, and we will take some video clips of machine working, operation, adjustment, disassembling and assembling.

All the wiring connection are adopting aviation plugs, which is very easy to joint together. Normally the workers only need to connect main power to the controlled boxes.

We will build an after-sale service chatting group to help the customer install and commission the machines.

4: Information to the customer regarding post-warranty repairs

Before the supply of the equipment, the customer will agree the following with the supplier:

- Exact geometry of the facing profiles, including all bending radii;

- Transversal and longitudinal positions of perforation  in profile;

- Co lour of the production equipment.

Before the shipment of the equipment to the customer the customer will perform initial inspection of the manufactured equipment at the premises of the supplier. The duration of the inspection: not less than one full business day. The supplier is allowed to ship the equipment to customer only if the evidence is obtained by the customer during this initial inspection that the equipment is in conformance with the requirements of these specifications. The supplier shall agree with the customer on the inspection date not later than 4 weeks before the inspection.

Communication language between the customer and the supplier: English, and Chinese.

5: Supply with machines:

Operational Manual and maintenance book

The drawing about machines

Technical and layout drawings of the machines

Machine details drawing with equipment details

Principle of electrical control system with drawing

Principle of hydraulic system with drawing

List of machines equipment parts with specification

List of spare parts supply with the machine