Box Beam Roll Forming Machine is a particular machine that is used to produce storage shelf box beam (also called cross beam or joist beam).

Forming by the rollers in a certain design, the box beam roll forming machine is able to roll the galvanized steel strip into a special box beam section shape continuously. Then the locking machine will roll and lock two pieces box beams together.

Box Beam Roll Forming Machine Main Components:

1, Decoiler: it is used to hold and decoiling the rolled steel coils. The decoiler can provide stable hydraulic pressure to expand the coils, ensure the coil flatness and straightness when it goes to the roll forming machine.

2, Flattening Station: with up 3 and bottom 4 shaft rollers, the coil flattening station is for leveling the steel strips, as they could be bent or twisted during the transportation and storage. As the box beam requires high flatness, so the accuracy and adjustability of the flatten rollers is particularly important.

3, Servo Feeding Device: the device is responsible for feeding the flattened steel coils into roll forming machine in accuracy and constantly. Normally it can be roller feeding or chain feeding. Coil strips feed by chain has a more stable speed in high speed production, as the chain transmission is more powerful.

4, Roll Forming Machine: as the most important part of the whole beam box machine, it mainly consists of a series of roller stations. Those rollers are specially designed by software such as COPRA, SOLIDWORKS, AutoCAD, Profili, Inventor, etc, according to the box beam profile drawing and size. Under the roller forming process, the steel strips gradually be formed to the required box beam shape. The rollers shape and arrangement normally need to be adjusted according to the final product shape.

5, Cutter: after the steel strips formed by the roll forming machine, the cutter will cut the beam box profiles in to required length according to the machine control program. The cutter type could be disc saw cutting, mold cutting, laser cutting, etc.

6, Stacking and Packing Machine: the already cut beam profiles will be transferred by roller conveyor to be stacked into a certain layers and numbers. Then it can be packed by automatic wrapping machine, so that it will be easier for storage and transportation.

7, Automatic Machine Control System: the whole beam box roll forming machine is equipped with an advanced machine production control system, which is used for monitoring and adjusting the working conditions of each machine system. The whole system includes PLC, HMI, Sensors, Electrical Motors, Servo Motors, etc, in order to achieve fully automatic and high accuracy production control.

8, Auxiliary Machines: except for the above-mentioned equipment, the whole beam box production line also could be equipped with locking machine, dust collecting system, lubrication system, etc to ensure the machine running in good and clean working conditions.

Detailed Specification of Beam Box Roll Forming Machine Components

a) Hydraulic Decoiler

1) Expanding type: Hydraulic expanding

2) Decoil type: Motorized active decoil

b) Flattening 

1) Flattening system: Top 3 and bottom 4 solid shaft, plus extra 4 pinch shafts.

2) Guiding system: Including guiding shaft and guiding rollers, its width is adjustable in order to suit for various steel strips.

3) Shaft material: CNC machining, quenching with tempering heat treatment, finish turning, polishing and chromeplate.

c) Main Roll Forming Machine

1) Roll stand: 24 main stations 

2) Transmission type: Gearbox for each roller stand

3) Machine base: Welded by H500 plate, with shot blasting and heat treatment

4) Roller material : GCR15, CNC machining with heat treatment, finish turning, polishing and chromeplate. HRC 58-60

5) Main shaft: SAE 5140, CNC machining, quenching with tempering heat treatment, finish turning, polishing and chromeplate.

d) Hydraulic Cutter

1) Type: Adopt post cut, automatic cut to length, quantity, etc.

2) Cutter material: SAE-AISI D3, quenching.

e) Power Supply & Control System

1) Control cabinet: 1 set. With ‘emergency stop’ switch.

2) Control handle: 1 set, for jog control during machine testing and production.

3) Operation platform: HMI & Button, with English language display.

f) Automatic Beam Profile Stacking Machine

1) Roller conveyor length: 12 meters

2) Stacking type: automatic over-turning and stacking the purlins according to programmed numbers and layers

3) Machine control system: PLC control, automatically synchronizing with the purlin roll forming machine. 

The Application of Box Beam

1, Support of rack shelf system

The box beam profiles made by box beam roll forming machine is mainly used to installed on the side of the rack shelf, share the weight of the shelf upright column. Those structures could fulfill different bearing requirements, and increase the whole storage shelf stability and support capacity.

2, Wide application area

The box beam profiles are widely used in various storage logistics shelf systems, including but not limited to pallet shelf, cantilever shelf, modular rack, moveable rack, etc. Those systems are widely used in warehouses, factories, supermarkets, etc for stores and managing different goods.

3, Increase logistics efficiency

Through the widely used beam box profiles made by the NOVOTEK beam box machine, it can build a more stable and solid rack shelf system, and then to increase the whole storage logistics efficiency and safety. As the development of the warehouse logistics, the demands of beam box roll forming machines will increase more in the future.

The Advantage and Disadvantage of Box Beam Roll Forming Machine

A) The advantages

a) High automation degree:

The cold roll forming machine normally adopts PLC control to ensure the high automation level production and reduce the manual intervention, increase the production efficiency.

The whole beam box machine needs only one operator, from the decoiler, flattening station, guiding and feeding, roll forming machine to cut, automatic stacking and packing, etc. It can save a lot of workers.

b) High Accuracy

The produced box beam is in high precision and good appearance, which can strictly fulfill the beam profile designing and size.

The roller materials are high quality gearbox use steel, through the quenching and chromplate, to ensure the whole roll forming process is stable and precision.

c) Flexibility

The roll forming machine is able to automatically adjust the product size continuously and automatically, to suitable for different beam box specifications and shapes.

The automatic user-friendly HMI interface is easy for operation.

d) Low energy consumption

The beam box machine is with low electricity kilo wart, so it meets the requirements of modern industrial energy conservation and emission reduction.

e) Safety protection

There are several safety protection systems to produce the worker’s safety during the beam box machine running.

B) The disadvantages:

a) High Investment Cost

The advanced high automatic box beam cold roll forming machine cost could be a big investment for the middle and small size factories.

b) Technical Threshold

Roll forming machine operation and maintenance requires operators to have certain professions and skills. If the machine operator is not familiar or improper, it could affect production efficiency and product quality.

c) Maintenance and After service

The transmission system, lubrication system, electrical and hydraulic system of the beam box roll forming machine requires regular maintenance to ensure the machine can run normally in long service life.

d) Raw material requirements

The galvanized steel quality and stability has a good affect of the final beam box profile quality. If steel thickness is not stable or not in good shape, then the product may have defect or not qualified. 

e) Noise and vibration

During the roll forming machine running, it may have a certain noise and vibration that may have an effect on the working conditions and the machine operators. So, it requires reducing noise and vibration levels with appropriate noise and shock reduction measures.

Installation and Commissioning of Beam Box Roll Forming Machine

1, Before machine installation, it needs to prepare a enough space factory. Its concrete floor should be strong enough to support the roll forming machine weight and transportation.

2, The installation starts from the assembly of roll forming machine structures. Needs to make sure the main roll forming machine structure is stable and flat, then to install the decoiler, flattening station, material feeding device, roll forming machine, cutting, stacking machine, etc.

3, To connect and adjust the machine according to suppliers’ installation and operation manual.

4, The electrical system must be strictly according to the beam box roll forming machine manufacturer’s electrical diagram and wire connecting drawings. The hydraulic system needs to be good connection to prevent oil leakage.

5, After the above installation work is done, then the roll forming machine needs a full commissioning which includes: empty run, check if every system works properly, if there are any noise or vibrations. Then the machine could run with raw material loading, to check the product quality and accuracy under the normal working conditions.