Storage Rack Roll Forming Machine
Storage Rack Roll Forming Machine is used for producing the upright racks for warehouse pallet racking system. It can uncoil, level, punch and continuously roll forming with automatic cutting to length.
Structural racking systems have a longer lead time, require skilled labor and more precise engineering. They also cost at a premium compared to a roll formed system.
The basic structure of a roll forming machine
Roll forming is a metal fabrication process that takes a strip of flat or unrolled sheet metal and transforms it into an engineered profile using successive sets of mated tool dies. The result is a complex, formed metal part that can be used for a wide variety of applications, including drywall profiles, metal ceilings, tubes and pipes, cable trays, solar profiles, shelving and storage racks, and more!
Because of its room temperature process, roll forming is also more energy efficient than other shaping methods like hot rack roll forming machine forming, and can be performed even after a finished coating or paint has been applied. This flexibility in material processing and shape configurations, combined with high-quality repeatability, makes roll forming the go-to solution for creating metal parts in large volumes.
There are a number of ways to configure a rack roll forming machine, but the basic structure is as follows:
The first step in the process is to cut the metal to a pre-determined length at the shears in the feed section of the machine. There are two main types of shears on a roll forming machine: pre-cut and post-cut. Both have their advantages, but the pre-cut shear allows for a cleaner cut and is often used when there are short length restrictions on the parts being made. Post-cut shears, on the other hand, have no such restrictions and can often be automated to speed up production.
Station rollers
The station rollers in a roll forming machine are a series of fixed rollers that both guide the metal strip and create the required bends at room temperature. Each set of rollers bends the strip a little more than the one before it, which allows for gradual shaping without overworking the material. This bending process can produce complex cross sections that are not possible with other processes.
This type of machine is designed to work with both ferrous and non-ferrous metals, allowing for a wide range of applications. The finished product can be used in manufacturing, commercial building, and aerospace industries. The process is also highly efficient and cost-effective. It can save up to 50% of the time it takes to manufacture products manually, and the materials involved in the fabrication process are typically much less expensive.
In some cases, secondary processing needs to be completed on the finished products before they can be shipped or stored. This can include punching holes, cutting to length, or adding slits to the metal strip. Some of these operations can be completed as the metal comes off the cut off press, but others may need to be done at another station. Many modern rack roll forming machines are equipped with PLC controllers, which allow the operator to enter commands for these tasks using a touch screen.
The cut off press
In the rack roll forming machine, the strip goes through a series of steps: Uncoiling-Punching Holes and Slots-Feeding and Guiding-Roll Forming-Cutting Off. A leveling machine is used to flatten the strips before punching holes and forming, and a rotary shear is used to cut off the finished product.
Structural racking systems use heavy-duty steel rails that connect to uprights to make a structure for storage of pallets. These structures can hold exponentially more weight than a roll formed system, but are more susceptible to damage from lift trucks. Since structural racking systems are bolted together, they take longer to deliver and require a higher premium.
Roll formed racking systems are made of light, higher-gauge components that snap into place. These systems are more easily assembled, and can be adjusted, disassembled, or replaced for facilities that store frequently changing SKUs or product sizes. They are also more quickly shipped, and have a lower premium.
When deciding which type of racking to rack roll forming machine use, it is important to consider the limiting factor of line speed on the tube mill. This can be a combination of factors, including mill drive power, reducer speed, weld power, and tube cooling section throughput. However, the primary limiting factor is likely to be the accelerator performance. This is because the accelerator must get up to speed before the die can make a cut.
The exit station
Rack Upright Roll Forming Machine is used to produce uprights for warehouse pallet rack system. These uprights are different in sizes and thicknesses and can be customized to meet specific load capacity requirements. They are usually manufactured from galvanized or CS Stainless Steel. Some of these columns are also designed with holes and slots.
The forming section is adapted to shape the so-called conical sheet, i.e. sheets that narrow towards one end. To do so, the rear end of the carriers 31, 32 are swung-out symmetrically from one another by reversing their intermediate parts 34 and locking these parts in their respective angular settings.
A first pair of forming stations 40, 44 situated on each side function to make grooves that extend parallel with the symmetry line of the sheet. This pair is optionally used in addition to or together with the other pair of forming stations, which are used to form the upstanding side edges 25 of the sheet.
The forming section is motor-driven for movement transverse to the sheet travel path, and the first pair of forming stations has forming rolls supported on free shafts. The other pairs of forming stations have forming rolls that are locked securely to their respective shafts. A cutter (63, 64) with profiled cutting edges is disposed downstream of the last forming station.