Strip Coil Processing unitsOur coil processing units (pre-processing) are capable of making complex and irregular internal cut patterns like holes, slots, notches at very high speeds on a continuous steel coils. This cutting unit can be added to any existing roll-forming line to increase line speeds near to maximum rolling speed.
Roll forming is commonly augmented with a range of auxiliary equipment to perform secondary operations, such as pre-notching, punching, embossing, marking, trimming. Matching overall line speeds with the maximum rolling speed increases the rolling machine’s utilization and ultimately results in higher productivity. CUTTING CAPABILITIES :
This process is called 2D PROFILING ! “ 2D Profiling is automated cutting of 2-dimensional complex forms like notches, rectangular and round cuts, along with holes & slots on metal bars, plates and sheets etc.” |
BENEFITS >>HIGH LINE SPEEDS > >
INCREASED UTILIZATION OF ROLL-FORMING PROCESS : For irregular and complex hole patterns unlike large number of regular holes, the most productive method typically involves a stock uncoiler, a plasma sheet processing unit, a roll forming machine, a cutoff machine, and a runout table. Plasma cutting process implies working from a continuous coil of material where the strip can be processed before entering the roll-former reaching production speeds average 30 to 55 meters per minute, but can be as high as 185 meters per minute. 2D CUTTING GIVES MORE FLEXIBILITY. Cuts of any shape & size, at any location ! o A wide variety of parts can be processed at fluctuating production volumes ! o Additional processing may include labelling using thermal marking / inkjet method. o These processing units are usually lightweight and can easily be moved from line to line if necessary. PRE-CUTTING AND PRE-NOTCHING CAN BE DONE ON THE SAME SETUP. (cut-to-length or for parts with certain types of notches). Coil strips can be pre-cut and processed, then fed into the roll former as individual strips while reaching line speeds up-to 15 to 76 meters per minute. Commonly used for low-volume production when notching is required that cannot be easily done using post-cut lines, or when multiple profile widths require expensive and or time consuming tool changeover. The plasma cutting technology can help make internal cuts with any dimension/shape and at any location on the material. Flexibility to make cuts of any dimension and at any location is a game changing ability in today’s low volume-high mix roll forming environment |
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FEATURES
Cutting zone is equipped with a 2-axis linear motion system for the plasma torch to travel over the sheet, while the material is fed inside with a servo feed controller. Incorporating this auxiliary equipment, the production can be a complete net-shape process, fully automated or nearly so if desired.
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2D Cutting gives more flexibility! Holes of any shape, size at any location . Wide variety of parts to be processed at fluctuating production volumes. !
“No change in tooling or die is required to obtain a different cut or at a different location.” Cutting occurs on the fly as the stock is moving, the plasma torch is designed to move with the strip to eliminate additional machine stop delays. Similar to servo feed punch presses the plasma unit can be operated with closed loop control, this reduces variation in length and location of the cut features(holes/slots). |
Capable of using DXF and NC tool paths! precise, repeatable cuts as per the part program .
The Intuitive Control Panel & Software interface can save setup time and out-cycle time significantly while the cutting operation can be left unattended for the entire coil for continuous rolling. Machine controls and peripherals can be controlled by one person from the operator’s console. The CAM, CNC software control is engineered & configured by us for extremely high exploitation of the system. |
Other production and operation advantages.
With today’s electrical controls and computer technology, it is possible and necessary to integrate the sheet processing equipment with a material requirements planning (MRP) system to schedule when and how much product is processed. Rolling Lengths, part quantities, and cut pattern info. can be directed from incoming orders and routed to the machine controls, with the inclusion of product specific labeling or inkjet marking to identify the product coming off the machine to the order for which it was made. This type of integration can added as a simple control upgrade or scheduled for future capital purchases. Our hardware and software infrastructure is designed to manipulate incoming orders to a data format that can be processed and transmitted to the plasma cutter's production queue.
With today’s electrical controls and computer technology, it is possible and necessary to integrate the sheet processing equipment with a material requirements planning (MRP) system to schedule when and how much product is processed. Rolling Lengths, part quantities, and cut pattern info. can be directed from incoming orders and routed to the machine controls, with the inclusion of product specific labeling or inkjet marking to identify the product coming off the machine to the order for which it was made. This type of integration can added as a simple control upgrade or scheduled for future capital purchases. Our hardware and software infrastructure is designed to manipulate incoming orders to a data format that can be processed and transmitted to the plasma cutter's production queue.
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Write/call our engineers to know more about how we can help you. Ph.Nos: +91 9987094580 or
+91 9167462818 Even if a standard machine won’t meet your needs, We can also provide custom equipment that’s built for your product. We work together with our customers in designing and creating each system around their product, to ensure first class quality and top performance of the end product. For an in-line integrated production system , we can combine multiple secondary processes to our unit. Our range of secondary processing capabilities include
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PROBLEM WE SOLVE COIL PROCESSING SCENARIO: [ INTERNAL FEATURES + END CUTTING]
For higher value addition in a roll-forming process, secondary operations like making internal cut features are combined in-line along with the rolling process. As the coil unwinds, conventionally the sheet has to pass through a series of hydraulic punch presses sequenced to make holes, slots, notches etc before entering the roll-former. Additional processes like punching, piercing, notching, welding, embossing, lancing, louvering, slitting, bending, cutting, bundling and labelling can be very easily integrated in-line with rolling process, but their efficiency decides the overall line speed in many cases.
CONVENTIONAL ROLL-FORMING SETUP :
Complexity in producing a roll-formed part can be due to multiple types of internal cut features to be required at irregular pattern or locations. For complex and irregular hole patterns, multiple configurations of press machines and tools are required. Tool cost and tool change time are also significant..
Requirement of holes and slots with flexibility in hole type and location. (roll-formed purlins & channels)
For easy erection and also to avoid wastage/rework at site fabricators using fastening methods often make holes and slots in low-medium numbers in an irregular pattern. The production cost and time taken for a steel part drastically changes with the number of complex internal cut features. So the overall process typically runs at speeds from 2 to 200 meters/min depending upon the desired configuration, tolerances required, additional ancillary or in-line operations, and material being formed.
CONVENTIONAL ROLL-FORMING SETUP :
Complexity in producing a roll-formed part can be due to multiple types of internal cut features to be required at irregular pattern or locations. For complex and irregular hole patterns, multiple configurations of press machines and tools are required. Tool cost and tool change time are also significant..
Requirement of holes and slots with flexibility in hole type and location. (roll-formed purlins & channels)
For easy erection and also to avoid wastage/rework at site fabricators using fastening methods often make holes and slots in low-medium numbers in an irregular pattern. The production cost and time taken for a steel part drastically changes with the number of complex internal cut features. So the overall process typically runs at speeds from 2 to 200 meters/min depending upon the desired configuration, tolerances required, additional ancillary or in-line operations, and material being formed.