TECHNICAL SPECIFICATIONS
PLASTERBOARD PROFILES : Ceiling U (29×24), Ceiling C (60×27), Wall U (30×50,30×75,30×100), Wall C (35×50,40×50,45×50), (35×75,40×75,45×75) ,(35×100,40×100,45×100)
PRODUCTION SPEED : 70 meters/minute (3,600 meters/hour), (1200 length/hour)
COLUMN WIDTH : 197mm (max. sheet opening)
MATERIAL THICKNESS : 0.30mm-0.60 mm (max.)
PRODUCTION LINE MACHINES
DECOILER (1 PIECE)
- Belt Width: 300 mm(max)
- Roll Material Handling Capacity: 2000 kg
- Roll Outer Diameter: 1300 mm(max)
- The tape decoiler will be non-motorized and braked type.
ROLL FORM MACHINE
- It has an advanced design consisting of 12 stations.
- There will be forming stations on the machine where the profile will be bent in stages.
- Shafts and rollers in the stations will be machined from Ç4140 material according to its own technique and hardened at 55-58 HRC. The shafts carrying the rollers will be bearing at both ends and will be designed and manufactured to produce profiles up to 200 mm sheet width.
- In order for the rollers to have a long life, hardening is done after CNC turning and grinding is done. After the last profile test is made, the hardened rollers are processed with ceramic cutting tools again when necessary until the desired quality and size of profile production is achieved.
- The bearing bearings on the machine are FAG/SKF brand.
- The surface of the forming rollers (for painted surface safety) will be polished.
- The drive gears of the rollers in the stations will be made of Ç8620 material and the surface will be hardened at 55-58HRc.
- After the forming stations on the machine, there will be a Straightening-Calibrating station for the profile to be in the desired linearity, planarity and buckling values.
- The rollform is designed in such a way that Omega profiles can be produced in addition to U and C profiles in the future.
HOLE DRILLING UNIT
- Some profiles require a cable pass-through hole. These holes are drilled in the hydraulic system.
- The molds on the punching press (H-shaped) will be made of Ç2389 cold work tool steel and hardened at 58-60 HRC.
CUT-TO-LENGTH FLYING SHEAR (IMPROVED DESIGN)
- The profile can be cut at the desired profile length (between 1.5 meters and 3 meters).
- It will be designed and manufactured to operate without stopping the production line.
- The hydraulic cutting unit will be moved by slides on linear rails.
- The cutting shear will be hydraulically driven and will have a cutting force of 5 tons (for profiles requiring greater cutting force in the future).
- Total electric motor power will be 4 KW (for cutting).
- The body carrying the cutting shear is movable and will be driven by SERVO MOTOR to ensure precise cutting length tolerance.
- Ç2389 cold work tool steel will be used in cutting dies and hardened at 58-60 HRC value
TILTING TABLE
- It will be used for removing the profiles from the production line.
- The stand will be 3 meters long.
CONTROL SYSTEM
- Profile length will be entered from the PLC operator panel and stored in memory.
- 1st class electrical materials, SIEMENS, MITSUBISHI, DELTA brand will be used in the system, including servo drivers.
- There will be emergency stop buttons on the roll forming machine (on the panel and body), cut to length scissors and tilting stand.
- Machines will be painted with epoxy based paint in RAL 5015 color.
- 380V +/- 10%, 3 Phase, 15 KW electricity supply for the production line is the responsibility of the customer.
- At least one roll of painted sheet metal will be provided by the customer for trials in our company.