This line was designed and manufactured by Custom Rollform Products for a manufacturer of air make-up units. The main body or structural enclosures of these units consist of two basic components, the frame rails and the intermediate supports.
|Both the frame rail and the intermediate support are manufactured from 16 gauge pre-painted or galvanized mild steel and both are produced from the same 9.625 (nine and five eighths) inch coil slit width.The intermediate support is primarily a 4” wide hat channel profile with 2” vertical flanges and 1” opposed horizontal edge flanges on both sides. The support hat channels need to be continuously punched down on both edge flanges and pre-notched and endformed on both the lead and trail ends. We produced a special combination cutoff and endform press that forms and folds both ends of the part inline as the parts are being cut-to-length.|
|The tubular frame rails were also manufactured on the same coil feed rollform system and produced from the same 16 gauge coil stock and slit width used for the hat channel profiles. Feeding the 4” hat channel profile through additional rollform tooling and stations produce the 2” square tubular frame rails. Using pre-tooled pre-notch and punch dies, a quick-change rollform tooling setup and two special pre-tooled cut-off and endform presses, both products are produced on the same coil fed system with a minimum amount of setup, downtime or scrap loss. Automatic changeovers from tubular frame rail to intermediate support make this a true just-in-time production system to improve your lean manufacturing capabilities.|
|The complete coil fed, punch, notch, rollform and endform system consist of a dual mandrel Decoiler, powered feeder straightener with sonic loop control, a series of pre-tooled hydraulic punch, notch dies with a programmable rollfeed, a special pre-tooled 24 station rollformer and two complete sets of cutoff and endform presses. The dual mandrel Decoiler is designed for a quick changeover from pre-painted to galvanized stock or pre-loading for the next coil to be run. The one set of coil mandrels can be changed over off line as the other set is feeding the coil strip into the system. The hydraulic punching and notching system consist of six pre-tooled inline press dies. Two presses are designed to continuously punch a combination slot / hole punch pattern down both edges of the coil strip in 12” increments. Two other presses are pre-tooled and inline to pre-punch and notch the lead and trail ends of the parts for either the frame rails or intermediate support sections. The other two press die units punch holes down the length of the tubular frame rails as required.||
The programmable rollfeed sequences the coil strip feed and cycles the presses through the AMS micro process controller. Parts can be keyboard entered or directly downloaded from an in-office AutoCAD file through a DXF file with the Eclipse option.
View of the Pre-Notch & Punch System. Edge slots and holes were progressively punched on 12″ increments. Lead and trail End Notching and Punching Press / Dies are pre-tooled inline for the Tubular Frame and intermediate support profiles. Part lengths and quantities are downloaded directly from an interoffice AutoCAD drawing of the individual Air Make-Up Housing required.The cutoff die for the intermediate Support Hat Channel Section was a Multi-Stage Hydraulically Activated System. It was designed to pilot and cutoff the pre-rollformed sections at the Pre-Notch as it forms the ends in one cycle. This eliminated second tangent forming operation and setups for various part lengths.To produce the 2″ square tubular rail form the 4″ hat channel profile, the channel web needs to be narrowed approximately 1/8″ to compensate for the bend allwoance. Then the coil strip is cleared from the first rollformer, the roll tooling is automatically repositioned using hydraulic cylinders on rollform stations 5 through 14. With all 24 rollform stations inline, roll tooling and properly indexed, the system will feed the coil strip through the complete set of rollform stations to manufacture the tubular frame rails. The rollform feed will sequence and feed the strip, form the frame rail profile, and feed it directly into the pre-tooled two (2) stage, punch emboss and cutoff presses. The two dies are designed to sense and pilot into the rollformed pre-notch, punching and embossing the lead and trail ends then into a combination punch, emboss and cutoff press die. Cutting, punching and forming the lead and trail ends automatically and inline eliminates any secondary off-line operations. The design of this framing system is very unique. The special interlocking tab ends on the frame rail produce a strong interlocking corner without any secondary parts or fixtures. The extruded holes and counter sinks formed in the cutoff die allow the parts to be directly fastened with self-threading screws.The fact that both parts are produced from the coil strip simplified the part changeover and flexibility of the sytstem.
|The manufacturer designs each air make-up system and direct downloads all the sizes and specifications directly into the microprocess controller. As the parts are produced the system produces a corresponding label to identify the part, usage and location in the assembly.
The pre-punched and notched coil strip will feed directly into the first stage pre-tooled 14 station rollformer designed to manufacture the intermediate support hat channel profile. As the formed part exits the rollformer it will feed directly into a specially designed hydraulic cutoff and endform press die. The die will sense and pilot off the rollformed, pre-notched opening. The die is designed to fold, form and swedge the leading and trailing ends of the intermediate support hat channel profile as it cuts the parts to length. Using a programmed cutoff and forming cycle, the die will double fold a return flange on both ends as it swedges the two side edge flanges together to produce a completed part automatically and inline. Using the programmed multistage form cycle, hydraulic cylinders are mounted above, below and on both sides of the cutoff and form press. All the forming operations are hydraulically sequenced and cycled, eliminating any mechanical cams or slides within the die. This combination cutoff and form press eliminates a series of down stream or additional off-line operations to complete this part. One of the most unique features of the system is the ability to automatically changeover from the intermediate support profile to the tubular frame rail in approximately two minutes, with a minimum amount of downtime, setup, or scrap loss. After the program punch notch system has run all the hat channel profiles the program changes the pre-notch within the coil strip and continues to punch and notch the strip for the tubular frame rails. The new pre-notch feeds out of the punch presses, through the slack loop and into the rollformer. There’s a pinch rollfeed and cutoff press mounted directly in front of the rollformer with sensors to read the pre-notch. When it reads a different pre-notch the rolls clamp and hold the strip as the shear die cuts the strip. The strip will continue through the rollformer post, cutting and endforming the remaining parts. Once all the parts are cleared from the rollformer and cutoff, the last 10 station rollformer will laterally shift inline with the first fourteen station rollformer making a total of 24 stations to produce the tubular frame rail. At the same time the intermediate support cutoff and form die is shuttled off-line.
View of the Combination Punch, Emboss and Cutoff Dies to complete the Tubular Interlocking Frame
|The overall accuracy of all the punching and notch is very critical to insure alignment of the parts and panels together. This system has been in service since 2003 producing parts for two of their manufacturing plants on a daily production schedule. Everything you see on this line was designed, built and manufactured by Custom Rollform Products. All our systems are engineered, wired, plumbed and programmed to insure we can service everything we sell. Buying a system built by a single source manufacturer will guarantee you quick service and years of quality production. Let Custom Rollform Products show you what you can do to increase your productions, minimum labor and scrap loss and improve your bottom line.|