Split Set Bolt Forming Machine Reliable 5 Line Upgrade
An old factory still runs its existing equipment, but the order specs have changed. Pipe diameter, material thickness, and product length are not what they were when the machine was bought. For a Split Set bolt forming machine, the question is not simply whether to replace old equipment. It's about whether the existing coverage still matches current production needs.
What a Split Set Rock Bolt Actually Requires
The split set rock bolt making machine produces rock bolts used in mine roadways, tunnel primary support, and slope reinforcement. These applications have different requirements for pipe diameter, material thickness, and length.
A complete Split Set rock bolt consists of several components. The pipe body is the main structure, the dome plate sits at the tail, the pipe end is necked as part of the assembly process, the ring is welded onto the pipe body, and finally all parts are welded into a finished product.
These components are made on different production lines. When order specs change, the question is not whether one machine can still run, but whether each production step still covers the requirement.
When One Machine No Longer Covers the Whole Process
Many factories start with one single machine for one process. That works at the beginning. But as order specs change, the limits of a single machine setup show up.
An existing single process machine may cover only one production step. Other components need outsourcing. When product specs change, the old machine's working range may not cover new order requirements. If orders require multiple specs, the machine's adjustment ability can become a bottleneck.
The real question is whether the existing coverage still matches current production needs.
From Single Machine to Five Independent Lines
The five line setup starts with one line for each component. The first four lines each produce one component, and the fifth line handles welding.
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Split Set Roll Forming Machine: cold forms steel strip into the pipe body
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Split Set Dome Plate Press Machine: punches holes and presses the dome plate shape on thick steel plate
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Split Set Necking Machine: reduces the pipe end diameter
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Split Set Ring Making Machine: bends wire into fixing rings
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Split Set Ring Welding Machine: welds all components into a finished rock bolt
A Split Set bolt forming machine with this layout lets each line handle a different component, and each line can be operated and managed separately.
Parameters for the Five Line Configuration
The Anchor Rod Cold Bending Roll Forming Machine handles the pipe body, while the other four lines cover dome plate, necking, ring making, and final welding. The parameters below come from the quotation. Each parameter belongs to its own production line, not to the whole system.
Split Set Roll Forming Machine Parameters
| Item | Parameter |
|---|---|
| Decoiler | 3 ton manual decoiler |
| Feeding rollers | 2 rollers |
| Guiding rollers | 2 rollers |
| Forming rollers | 7 rollers |
| Transmission | Gearbox |
| Voltage | 380V 50Hz 3 phase (customizable) |
| Frame structure | Heavy duty cast steel frame with middle plate welded base |
| Forming speed | 0 to 15 m/min |
| Material thickness range | 2.5 to 3.5 mm |
| Pipe outer diameter | 35 mm / 46 mm |
| Shaft diameter | 70 mm |
| Roller material | Cr12 with quenching treatment |
| Hydraulic station power | 7.5 kW |
| PLC control | Delta |
| Shearing type | Hydraulic stop shearing with notch cutting at the same time |
| Receiving table | 2.5 m per piece |
Split Set Dome Plate Press Machine Parameters
| Item | Parameter |
|---|---|
| Hydraulic station power | 15 kW |
| Voltage | 380V 60Hz 3 phase (customizable) |
| Processing speed | 0 to 10 pieces/min |
| Mold material | Cr12MoV |
| Material thickness | 5.0 mm |
Split Set Necking Machine Parameters
| Item | Parameter |
|---|---|
| Hydraulic motor power | 3 kW |
| Voltage | 380V 50Hz 3 phase (customizable) |
| Mold material | GCr12 |
Split Set Ring Making Machine Parameters
| Item | Parameter |
|---|---|
| Drive motor power | 2.2 kW |
| Voltage | 380V 50Hz 3 phase (customizable) |
| Mold material | GCr12 |
| Wire diameter | 6 to 8 mm |
| Speed | 40 to 45 pieces/min |
Split Set Ring Welding Machine Parameters
| Item | Parameter |
|---|---|
| Welding type | TIG |
| Welding power | Model 350 |
| Voltage | 380V 60Hz 3 phase (customizable) |
| Pipe diameter range | 28 to 50 mm |
| Rock bolt length | 1.2 to 2.8 m |
| Welding speed | 4 pieces/min |
Advantages of the Five Line Upgrade
A Split Set bolt forming machine with five lines lets an old factory move from single process production to a complete Split Set rock bolt production solution.
Each component has a dedicated production line, so no single machine has to handle different processes with different motion requirements.
Each production line can be operated and managed separately, which gives the factory more control over how each step runs.
When order specs change, the factory can check coverage step by step. A Split Set bolt forming machine with this layout does not force the factory to replace everything at once.
What the Three Key Specifications Mean for an Old Factory
Three specs directly affect the upgrade decision: pipe diameter, material thickness, and product length.
Pipe diameter. The pipe body forming line handles outer diameters of 35mm and 46mm. If current orders fall within this range and the old machine already covers it, this item is not a reason to upgrade. If orders require two diameters but the old machine covers only one, then check the new line's coverage.
Material thickness. The pipe body thickness range is 2.5 to 3.5mm, which belongs to the roll forming line. The dome plate machine handles material thickness of 5.0mm, which belongs to the dome plate press line. These two thicknesses apply to different components and different production lines. Check them separately.
Product length. The welding machine works with rock bolt lengths from 1.2 to 2.8m. The welding step is where the final length is set. If the old setup only makes one fixed length and current orders need different lengths, this range becomes a decision factor.
What to Confirm Before Replacing Old Equipment
Before deciding on an upgrade for a Split Set bolt forming machine, check three things.
First, what can the old machine produce now. Look at the pipe diameter, thickness, and length it covers.
Second, what current orders require. Compare the specs directly.
Third, which steps fall outside the old machine's coverage. If only one step is missing, adding one line may be enough. If the factory needs full rock bolt production, the five line configuration on an Anchor Rod Forming Machine is the natural direction.
If you want to discuss a specific configuration, contact us.
An upgrade for a Split Set bolt forming machine is not just about replacing one machine with another. It's about checking whether the old coverage still fits current orders. Pipe diameter, pipe thickness, dome plate thickness, and finished rock bolt length each belong to different production lines. Check them one by one.
