What equipment is used for the production of corrugated sheets

Manual machine for bending corrugated sheets

A handheld machine is a device that requires no external power source, just a small room or shed on a construction site and two workers. This is a good option for a small construction company if the construction of the facility does not require a lot of products made from corrugated sheets. Sometimes it is too expensive to deliver them to the site, and then you can arrange for the production of corrugated sheeting right on site - for example, making additional elements for the roof.

Compound

1. A bending mechanism standing on a bed, which includes hinges and gears driven by hand levers, as well as a bending matrix and a pressure beam.
2. Feeding table on which the workpiece is placed. It is advanced to the bending mechanism, in which it is processed. Also included is a roller blade that cuts steel.
3. A receiving table and a plate, with the help of which the desired bending angle is set and the rest of the sheet is fixed.

During one work shift, about 120 sheets of corrugated sheets (1×2.5 m) are produced. The machine pays for itself quite quickly, especially if it is located at a construction site and you do not have to spend money on the delivery of corrugated sheets - only on the delivery of the workpiece. The latter is carbon or stainless steel or copper/aluminium, because polymer-coated material may lose its aesthetic appearance during the bending process - this requires special, more expensive machines.

This is what working with a manual machine looks like:

The resulting sheets are usually no more than 2-2.5 meters in length, because otherwise there may be uneven bending of the profile. The reason is different compression forces in different parts of the sealing lip.

The production process can be described as a series of steps:

1. The sheet is fixed on the table with a clamp.
2. The steel beam forms a trapezoid or profile wave.
3. Control sensors stop the bending process at the right moment.
4. The bending angle is controlled using a scale, as is the travel of the traverse. The maximum is 150°.
5. After bending, the roll unwinds.
6. The process is repeated until the required length is reached, after which the sheet is cut.

Buy a machine for the production of corrugated sheets: why?

A machine for the production of corrugated sheets from China produces a material that is widely used in modern construction. The resulting profile is used for installation:

• Sten;
• Partitions;
• Suspended ceilings;
• Roofs;
• Protection and finishing of facades;
• Buildings for various purposes;
• Foundation formwork;
• Awnings.

Machines for corrugated sheets made in China are easy to operate, since the automatic control system is Russified and also has a menu in Chinese and English.

Automatic line for the production of corrugated sheets

This automated equipment processes cold-rolled and color-coated steel with high productivity. If delivery of finished profiled sheets is very expensive, then sometimes you can install a mobile automatic line at the construction site. But for serious scale, a full-fledged line with different mills is needed. The line operation scheme is as follows:

1) the workpiece is fed;

2) bending occurs and the rolled strip is formed in accordance with the required configurations;

3) guillotine shears cut the sheet;

4) the product is being prepared for packaging.

This is how corrugated sheets are manufactured at our enterprise:

Line composition:

1) a software block with which the line is turned on and off, and work programs that determine the height of the corrugation are set;

2) the unwinder is a shaft on which the sheet is put on and held to be fixed to the place of profiling;

3) rolling machine - the main element on which the metal is bent into a profiled sheet according to the program;

4) guillotine shears or, more simply put, a trimming press that cuts a profile according to specified parameters;

5) receiving table - a flat surface, the dimensions of which correspond to the dimensions of the product; this is the place where finished sheets are stacked and products are packaged for shipment to the warehouse.

Types of rolling

There are two types of rolling:

1) wedge or sequential - first the middle of the sheet is rolled, and then the outer corrugations are rolled;

2) simultaneous scheme, in which all the corrugations of the profiled sheet are rolled overnight.

It is preferable to use the latter scheme, since in this case the tightening will be the same. When rolling sequentially, due to the fact that the edges and the middle are rolled separately, herringbones and ripples may appear along the edges, but with simultaneous rolling, this is excluded.

Advantages of automated lines

The production of corrugated sheets with an automated line provides not only convenience, but also other advantages:

• productivity reaches 1000 m² per shift, which is several times more than that of a manual machine;
• easy operation, for which one person is enough;
• a wide arsenal of programs, thanks to which any sheets can be produced according to special orders;
• absolute geometry of sheets;
• corrugations that meet the requirements of GOST.

Of course, the premises where such equipment is located are subject to quite strict requirements. The line is expensive, and each brand of corrugated sheet requires a separate mill, which only serious manufacturers can do. In addition, it can be equipped with additional equipment that simplifies the production process.

Rolling mill rollers

From the unwinder, metal sheets fall onto rollers, where they are formed according to the set program. The shape of the rollers determines the characteristics of the sheet profile. They can be solid or stacked - consist of several washers, rings and bushings. The latter option makes it possible to quickly change the size and shape of the relief or select the desired ornament.

Industrial production lines for the production of corrugated sheets

If to profile the surface of one sheet of metal on a manual machine it is necessary to perform 10-12 operations, industrial machines are production lines that can produce up to 32 linear meters of profiled sheet per minute . Moreover, their productivity practically does not depend on the profile height and sheet dimensions of the finished product. Moreover, the longer the profiled sheet, the shorter the operating time of the guillotine shears and the greater the productivity of the line.

As mentioned above, the high demand for profiled metal sheets and the simplicity of its manufacturing technology have become the reason that many machine-building enterprises have launched the production of equipment for the production of corrugated sheets. Therefore, buying equipment for the production of corrugated sheets today is not difficult. You just need to decide what brand of corrugated sheeting will be produced.

Worth remembering

The greater the height of the trapezoid and the more complex the profile shape, the more expensive the set of necessary equipment will cost.
The price also depends significantly on the manufacturing company. This could be equipment from a well-known European brand, a Russian company, or a machine made in the People's Republic of China. Chinese equipment for the production of corrugated sheets is in great demand in Russia and the CIS countries, the price of which is significantly lower than that of European or Russian analogues.

An example of equipment for the production of corrugated sheets using the method of sequential profiling

The equipment necessary to equip the production lines on which corrugated sheeting is manufactured has the following main characteristics :

• initial raw materials - thin-sheet galvanized steel coils or steel with a protective and decorative polymer coating;
• maximum roll width - 1250 mm;
• sheet steel thickness - 0.45-1.2 mm;
• equipment operating mode - automatic;
• tape feeding mode from a roll - semi-automatic;
• installed power of electrical equipment - 13-17 kW;
• installation dimensions of the line are about 18000×2600×1700 mm;
• productivity - from 20 to 32 lm. profiled sheet per min.

The industrial line for the production of corrugated sheets consists of the following main units.

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Double-post or cantilever unwinder

This unit is designed for installing a roll of thin sheet steel used as the starting material for the manufacture of profiled sheets. From the uncoiler, the steel is fed into the rolling mill.

Unwinders for equipment for the production of corrugated sheets

On modern automated lines, the sheet feeding speed is controlled by an automation system, which allows the operation of the unwinder to be synchronized with other technological operations. On many rolling mills, a special roller knife is installed on the unwinder, which automatically cuts the steel strip when it is necessary to replace the roll.

The characteristics of the double bearing unwinder are as follows:

• maximum steel coil weight - 10 tons;
• electric drive power - 3 kW;
• internal diameter of the steel roll (fitting size) - 480-650 mm;
• overall dimensions - 2600×1600×1700 mm;
• device weight - 1100 kg.

Multi-stand rolling mill

It is here that the production of corrugated sheets directly takes place - the rolling mill equipment consists of several basic elements. This is a metal frame with rollers mounted on rotating shafts, an electric motor and a pneumatic or oil station.

The shape of the rollers corresponds to the profile of the produced metal sheet. Using a hydraulic or pneumatic drive, the rollers “squeeze” the steel strip, gradually forming the desired profile as it moves. The shafts with rollers attached to them are driven into rotation by an electric drive from an engine and a chain drive.

Rolling mill equipment for the production of profiled sheets

Profile formation can occur according to a simultaneous or sequential scheme. With simultaneous rolling technology, all corrugations of the profiled sheet begin to form from the first stand of the rolling mill. This guarantees uniform profiling and makes it possible to reduce the dimensions of the rolling mill.

The main characteristics of rolling mills are as follows:

• number of working stands - from 10 to 15;
• electric drive power - 6-9 kW;
• overall dimensions (length, height, width) - 7000-12000×1600×1400 mm.

Electromechanical or pneumatic guillotine shears

The shears are installed on the last stand of the rolling mill and are designed to cut the finished sheet of corrugated sheets to a given length. Guillotine shears are equipped with special knives that have the shape of a profile of the sheet surface. This allows you to avoid creasing the edges of the corrugated sheet when cutting . This is especially important for load-bearing corrugated sheets with a high trapezoid profile height.

Pneumatic shears for cutting manufactured corrugated sheets

The characteristics of the cutting device are as follows:

• electric drive power - 3 kW;
• overall dimensions - 1500×400×1100 mm;
• weight - 550 kg.

Receiver

This unit completes the technological chain for the production of profiled sheets. The purpose of the receiving device is acceptance and temporary storage of finished corrugated sheets. From here the finished products are sent to the packaging area. The receiving devices of many modern rolling lines have retractable trolleys and automated stackers.

Receiving device for finished products

The characteristics of the receiving device are as follows:

• overall dimensions (length, width, height) - 9000-1400×1350×1200 mm;
• weight - 350 kg.

Automated line control system

Last but not least is the automation system for the corrugated sheet production line. Modern automated control systems for such lines are created on the basis of advanced multifunctional industrial controllers. They provide control of all technological operations with synchronization of the entire system.

Automated control systems can control the rolling speed with a given optimization function according to the criterion of quality-performance or quantity-length. They can also manage the shipment cycle and keep records of finished products, while adjusting the required duration of technological breaks.

Automatic control panel for equipment for the production of corrugated sheets

All this is possible thanks to the installation of a large number of various sensors that ensure the transmission of all necessary information to the system.

The control panel of the automatic control system displays signal indicators for the operation of all units of the production line; it is also equipped with a warning system for the occurrence of an emergency.

The above briefly describes the standard configuration of lines for the production of corrugated sheets; equipment, the price of which differs from the base cost, most often includes additional options .

This may be a roller cutter for cutting the sheet steel fed from the decoiler, an automated stacker or a stacker mounted on the receiving device.
Sometimes lines for the production of corrugated sheets are equipped with auto- or electric forklifts. They are used to install thin-sheet steel coils on an unwinder and transport finished products from the receiving facility to the warehouse. The cost of production lines depending on the completeness of delivery

You can buy equipment for corrugated sheets by paying an advance payment to the supplier.
It is usually within 10% of the production line cost. The balance of the amount is paid when the equipment is ready for shipment to the consumer. Acceptance can be carried out both at the manufacturer’s plant and directly at the customer’s. Estimated prices of production lines for the production of various grades of profiled sheets

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Team oprofnastile.ru

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Double-tier lines

Two-tier lines make it possible to alternately produce two types of corrugated sheets (from thin sheet rolled steel with galvanized or polymer coating). It is possible to produce wall and roofing corrugated sheets, and on the second tier - metal tiles made of galvanized steel and metal with a polymer/paint and decorative protective coating. Such lines allow you to save:

• money, because there is no need to buy an additional unwinder and automation system;
• production area, because the lines are located one above the other.

A complete set of equipment allows us to produce a wide range of products with the best characteristics. If you choose corrugated sheeting made on factory equipment, you can be confident in its quality.

Automated two-tier line for the production of corrugated sheets in action:

Equipment for the production of corrugated sheets

Machines for the production of corrugated sheets from China, supplied by our company, have different parameters and prices, which allows customers to choose the best option. We offer equipment producing:

• Standard profile flooring (C8, C10, C13, C17, C18, C20, C44);
• High-precision and especially durable materials (H35, N57, N44, N60, N75, N114);
• Fashionable embossed metal tiles (type Monterrey, Andalusia, etc.).

We have a permanent base of trusted suppliers and experience in working with foreign and Russian customers. By placing an order with us, you will provide your company with modern and functional equipment.

If you are looking for the most productive equipment, we recommend paying attention to two-tier lines that produce twice as many products per minute.

Restrictions

The only limitation is the inability to produce profiled sheets longer than two meters. But, as practice shows, it is sheets up to two meters long that are the most in demand today; they are considered universal. This means that you should not be afraid that the products will remain in storage. And one moment. This machine cannot be used to produce corrugated sheets coated with paint or polymer. Here only galvanized sheet is used as raw material.

But in order for your products to be in greater demand than those of your competitors, it is recommended to organize a workshop for painting this material next to the workshop for the production of corrugated sheets. This is also a simple process in which you will not need to invest a large amount of money. By combining two technological processes into a single production, you can benefit from the assortment in terms of color design. In addition, double protection of corrugated sheets is an additional bonus to the quality of the material.

Manual machine for corrugated sheeting - what are the advantages of such a solution?

Currently, many machine-building enterprises produce such equipment, and anyone can buy a manual machine for corrugated sheeting. Its main advantage is that such a machine does not require external energy sources to operate, since human physical strength is sufficient to operate it.

In order to set up the production of profiled sheets on a manual machine in a matter of hours, you only need a small room (although even this is not necessary, just an ordinary shed is enough) and two workers familiar with the structure of the machine.

Russian manual machine for the production of corrugated sheets

A manual machine for making corrugated sheets is indispensable for a small construction company, which is often faced with the need to use a small number of products from profiled sheets. It is simply not practical to order them because the cost of delivery to the site is too high.

With the help of such a machine, it is possible to produce directly on the construction site various additional elements necessary, for example, when installing a roof. A manual machine for the production of corrugated sheets is so simple that it requires virtually no maintenance other than periodic lubrication.

The advantages of such a machine include its relatively low cost. A manual machine for corrugated sheets, the price of which is about 2000 US dollars, will pay for itself after producing 750-800 m² of profiled sheets, which is approximately its daily productivity. And this does not take into account the cost of delivering this corrugated sheet to the construction site if it is purchased. But you can also buy a machine that has already been used. It will cost several times less, and will last for many more years, since the forces acting on its main components are negligible and their wear is minimal.

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