Production Line for Metal Shelf

GENERAL FEATURES

• Metal shelf systems are used for rendering the storing space and time efficiently in modern supermarkets and Commercial buildings.
• Recent years ,there is a high demand for supermarkets hence metal shelf systems.
• It enables regular , efficient and fast storage of articles .Supermarkets shelves. They have miscellaneous design, model and capacity depending upon storage aims.

APPLICATIONS

• Supermarkets
• Warehouse areas
• Documentation departments
• Libraries

STANDARD FEATURES

PRODUCT

• Production speed :4 pieces/ minute
• Material :Galvanize steel ,Black steel
• Product length : 500mm-1.200mm
• Product width : 200mm-800mm
• Material  thickness: 0.60mm-1.0mm

PRODUCTION PROCESSES

• Coils are adjusted by means hydraulic. 
• Coil material is straightened before corner cutting and punching.
• Coil is pulled to perform corner cutting and punching by servo puller.
• Corner cutting and punching are carried out. Length  is then cut by hydraulic shear.
• Punched sheet transferred to roll forming machine.
• Punched sheet is formed at Roll forming machine
• Sheet long edges formed is transferred to  front bending unit for short edge bending.
• The sheet with three sides bended is transferred to rear bending unit automatically by means of conveyor system between the front and rear bending units.
• The 4th side of sheet is formed on rear bending unit.

MACHINERY &EQUIPMENT ON PRODUCTION LINE

1) DE-COILER-Hydraulic

2 STRAIGHTENER-MOTORIZED

3) CORNER CUTTING PRESSES-HYDRAULIC

4) DIE SET-CORNER CUTTING

5) PUNCHING PRESSES-HYDRAULIC

6) DIE SET-PUNCHING

7) SERVO PULLER

8) HYDRAULIC SHEAR-LENGTH CUTTING

9) TRANSFER CONVEYOR-I

10) ROLLFORM MACHINE

11) TRANSFER CONVEYOR-II

12) FRONT BENDING

13) REAR BENDING

14-EXIT CONVEYOR-III

DE-COILER (Hydraulic)

• Capacity: 8t
• Material Thickness: 0.50mm-1.0mm, Coil width: 1000mm
• Coil outside diameter: 1200mm /Coil inside diameter: 400mm-550mm

2) STRAIGHTENER

• Coil width: 900mm (max.) / coil thickness: 0.50mm-1.2mm
• 4 each upper pinch roll and 5 each lower pinch rolls combination

3) CORNER CUTTING PRESSES (HYDRAULIC C Frame)

• Capacity: 40 t/ each-total: 2 units
• Total hydraulic capacity: 80t

4) DIE SET FOR CORNER CUTTING (2 sets)

• Punch and die parts from cold work tool steels and hardened to HRC 60-62

5) PUNCHING PRESSES (HYDRAULIC C Frame)

• Capacity: 60 t/ each-total 2units
• Total hydraulic capacity: 120 t
• Steel welded structure machined and painted
• Each press is translated on slide ways &rails in order to adjust shelf width automatically
• Total power for hydraulic system: 22 kW (for corner cutting & punching)

6) DIE SET-PUNCHING (2 sets)

• Punch and die parts from cold work alloyed tool steels (Sverker21&arne-ASSAB UDDEHOLM) and hardened to HRC 60-62

7) SERVO PULLER

• Direct drive-Servo motor & gear reducer combination
• Rolls made from Nickel steel and hardened
• Pneumatic pressing mechanism for rolls

8) SHEAR-LENGTH CUTTING (Mechanical) 

• Capacity: 1000mm length
• Steel welded structure machined and painted

9) TRANSFER CONVEYOR -  I

• Function: transfer from punched and precut sheet from shear to roll forming machine
• It is motorized and operated with the line in synchronization

10-ROLLFORMING MACHINE –Total 23 stations

• Type: Duplex mill
• Adjustable Inlet guide rolls
• Stands on operator side is moved as a group on slide ways and rails for different shelve width automatically.
• Movable operator side –Fixed drive side
• Shafts are supported one side (cantilever) and other side is free
• Shafts made from Nickel steel precisely machined , hardened and grinded
• Rollers made from Nickel steel precisely machined, hardened, grinded, re-machined after hardened for long lifetime.
• Power is transferred from main gear reducer to stations by gear reducers.
• Upper rollers is adjustable for different material thickness.
• Bearings.SKF/FAG/TIMKEN
• Motor Power:15 kW

11) TRANSFER CONVEYOR - II

• It is motorized and operated with the line in synchronization
• Pneumatic stop unit at every 1.5 meter length

12 & 14 FRONT &REAR BENDİNG PRESSES

• Hydraulic bending-Each press at 10 t bending capacity

13) TRANSFER CONVEYOR - III

• Function: transfer from punched and precut sheet from shear to roll forming machine
• It is motorized and operated with the line in synchronization
• Length:1.5 meter -0.37 kW electric motor

14) AUTOMATION SYSTEM

• Two modes of operation ;Manual/Automatic
• SIEMENS / MITSUBISHI PLC touch screen and Servo controllers
• SIEMENS/MOELLER/TELEMECHANIQE electricals.
• Synchronized operation on the line