1. Equipment Composition
The production line utilizes automated integrated control and consists of the following main units:
1). Uncoiler: Supports and releases the steel coil; equipped with a braking/damping device to prevent the strip from unraveling.
2). Guiding and Leveling Unit: Corrects transverse warping of the steel strip to ensure the material is flat and straight before entering the forming section.
3). Servo Feeding and Pre-punching System: Driven by a servo motor, this system precisely punches installation holes (oval or round) at set intervals on the web of the flat steel strip.
4). Main Roll-Forming Unit: Composed of arch-style stands, a transmission gearbox, and multiple stages (typically 12–18 passes) of progressive forming rollers. The rollers are typically made from GCr15 bearing steel or high-chromium alloy steel and undergo quenching treatment to ensure wear resistance during long-term operation.
5). Punching and Cutting Unit: Uses hydraulic or mechanical shearing to cut the profile to the required length while it is in motion; the cut is smooth and burr-free, eliminating the need for secondary sawing.
6). PLC Control System: Features a touchscreen HMI (Human-Machine Interface) integrating functions such as length setting, punching frequency adjustment, fault self-diagnosis, and production counting.
2. Standard Process Flow:
Uncoiling → Feeding and Leveling → Servo Punching → Multi-stage Roll Forming → Fixed-length Punching and Cutting → Finished Product Discharge
3. Technical Parameters
| Item | Parameter | Remarks |
| Frame | 40# National Standard I‑steel | Integrated welded structure |
| Roller Material | Cr12Mo1V1 | Vacuum quenched |
| Main Shaft | φ90, 40Cr | Quenched and tempered |
| Forming Stands | 20 | |
| Main Motor Power | 25kW, variable frequency | |
| Main Drive Gearbox | K107 | |
| Transmission Type | 1.2‑inch double‑row chain drive | |
| Cutting Method | Hydraulic cutting | Hydraulic station motor: 11kW |
| Punching Method | Hydraulic punching | |
| Uncoiler | 5T, trolley feeding | Hydraulic station motor: 2.2kW |
| Electrical Control System | Siemens & Schneider PLC | |
| Hydraulic System | Beijing Huade | |
| Total Production Line Length | Approx. 25 m | |
| Main Unit Weight | Approx. 12 tons | |
| Raw Material Thickness | 3.0 mm | Q235 galvanized coil |
| Raw Material Width | 175mm‑480mm | |
| Production Speed | 25‑30 m/min |

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