Cable Tray Forming Machine

Машина для формовки кабельных лотков

Cable Tray Forming Machine

Cable Tray Forming Machine

Машина для формовки кабельных лотков

The high-quality model is designed around six key dimensions: protecting the glaze surface from scratches, achieving precise molding accuracy, ensuring robust structural rigidity, providing intelligent stability, offering wear resistance and long service life, and compatibility with color-coated substrates—distinguishing it from conventional simple tile pressing equipment.

Rolling system: Wear-resistant glaze protection and progressive forming (the most critical differentiator)

Glazed painted panels are particularly vulnerable to scratches from rollers; high-end models feature specialized optimizations to address this issue.

1. Roll material and heat treatment: The roll core is made of GCr15/Cr12MoV die steel, precision-machined via CNC machining, with vacuum quenched hardness of HRC 58–62; the surface features a thickened hard chrome polishing coating that prevents scratches on color-coated surfaces. Conventional equipment typically uses only 45# steel with simple chromium plating, which is highly susceptible to scratching the paint finish.
2. Multi-pass progressive roller pressing process:Featuring 18–24 forming passes, it applies gradual pressure to the sheet in segments to prevent surface cracking or peeling caused by excessive single-pressure applications; ensures uniform depth of wave and bamboo-joint patterns with strong three-dimensional tile appearance, with wave height deviation ≤ ±0.2 mm and tile overlap gap ≤ 0.3 mm, significantly enhancing roof waterproof performance.
3. Large-diameter solid roller shaft: Main shaft diameter 75–90 mm, made of solid forged steel with heavy-duty self-aligning bearings; operates without vibration or plate deviation, ensuring uniform load distribution across the entire glaze surface without wear marks.
4. Optional film-coating synchronization mechanism: High-end production lines are equipped with online film-coating devices, ensuring the entire manufacturing process is covered with protective film over the glaze surface, resulting in finished products free from scratches and eliminating the need for subsequent film application steps.

Heavy-duty structural design: high rigidity and long-term deformation resistance

Thickened H-shaped steel integral welding frame: Constructed with a National Standard H-type main beam (350–450 mm thick) reinforced with 16–20 mm steel plates; the entire assembly undergoes high-temperature stress-relief annealing to eliminate welding internal stresses, enabling high-speed continuous production without vibration and resistance to lateral bending or distortion under long-term heavy loads.

Separate independent stamping station: A standalone hydraulic stamping unit featuring bamboo-joint-style antique patterns, equipped with a four-column vertical guidance system that ensures precise alignment, uniform pattern depth, and prevents damage to the panel’s glaze surface. The compact integrated model, however, is prone to paint scratching and pattern misalignment during operation.

Robust structural design with counterweight: The unit weighs 6–8 tons, featuring high-speed operation with vibration damping and noise reduction, ensuring stable 24/7 production with an average Mean Time Between Failures (MTBF) of ≥6,000 hours.

Servo Intelligent Control System: High Precision, Fully Automatic, Material Protection

PLC-controlled servo closed-loop fixed-length feeding system (standard configuration for high-end models): integrates Siemens/Mitsubishi/Delta PLCs with servo motors and high-precision encoders, achieving a length cutting error of ≤±1 mm; the servo system ensures smooth acceleration/deceleration, prevents impact during plate startup/stop, and eliminates surface stretching or wrinkling; conventional chain drives exhibit large clearance, are prone to scratching painted plates, and cause significant dimensional deviations.

Touch-based intelligent human-machine interface: Stores over 10 tile parameter sets, enabling one-click switching between board types (840,850,1050, bamboo-cell tiles, etc.); features automatic counting, production statistics, fault code self-diagnosis alarms, and easy operation with minimal training for beginners.

End-to-end integrated collaboration:Synchronized timing for feeding, rolling, embossing, and cutting; precise coordination between stamping and feeding to prevent pattern misalignment or glaze detachment from the sheet. Equipped with a remote IoT module for cloud-based monitoring, remote debugging, and fault diagnosis.

Energy-efficient silent drive: Servo drives consume 15%–23% less power than conventional frequency conversion models, featuring smooth start/stop operation and low noise levels, thereby enhancing workshop productivity.

Hydraulic shearing system: produces smooth cuts free from burrs and glaze detachment

1. Cr12MoV wear-resistant shear blade:Features a rear-cut hydraulic cutting mechanism; the blade is quenched and ground to produce smooth cuts without burrs, preventing damage to the color-coated glaze layer on sheet edges; suitable for thin materials (0.3–0.8 mm) and universally applicable to PPGI/PPGL/AlMgM steel plates.
2. Hydraulic pressure stabilization system:Standardly equipped with air-cooled/water-cooled hydraulic stations, maintaining stable pressure at 16–25 MPa with minimal shear impact, ensuring no warping at plate edges or cracking of the glaze surface; featuring overload pressure relief protection to prevent equipment and plates from being damaged by blade entrapment.

Wide material compatibility and high yield rate of finished products

1. Substrate compatibility: Compatible with all glazed color-coated coils ranging from 0.2 to 1.0 mm in diameter, including color steel sheets, aluminum-zinc coated surfaces, galvanized surfaces, and aluminum-magnesium-manganese antique-glazed panels; available in standard widths of 1000 mm or 1220 mm.
2. Extremely low scrap rate: The machine features integrated alignment correction, cushioning, and glaze protection mechanisms, ensuring a stable product pass rate of ≥99.2%. This significantly reduces material waste caused by scratches, wrinkles, or defective patterns, thereby achieving long-term savings in color-coated roll material costs.
3. High-speed, stable production capacity: Standard models feature a forming line speed of 25–32 m/min; high-speed dual-line models achieve up to 120 m/min, with a daily output exceeding 8,000 m² of roof tiles per shift, making them ideal for mass production in large-scale tile factories.

Durable and easy to maintain; comes with comprehensive safety features for all scenarios.

1. Double the service life of vulnerable components: Rollers, blades, and the main shaft are strengthened through heat treatment, requiring no large-scale replacement during normal operation for 5–10 years, thereby reducing downtime for maintenance; the transmission employs a sealed gearbox system with dust and rust resistance, exhibiting lower wear compared to chain drives.
2. Comprehensive safety features:Fully enclosed roller protective covers, front/rear emergency stop buttons, hydraulic overload protection, and leakage current power-off protection, compliant with CE and ISO industrial safety standards.
3. Modular and easy-to-maintain design:The forming station, hydraulic station, and electrical control cabinet adopt a modular, compartmentalized design, facilitating convenient assembly and disassembly of components; each unit comes equipped with a complete set of tools, consumable spare parts, and comprehensive electrical drawings.

Summarize Core Differentiation (Key Factors for Selection)

1. Standard model: Chain drive, standard 45# pulley, stress-free frame, prone to scratching the glaze surface, dimensional tolerance of 2–3 mm;
2. High-quality glazed roof panel forming machine: Equipped with servo closed-loop feeding system, precision quenched-chromed rollers, heavy-duty annealing frame, independent buffer stamping mechanism, full-glaze protection design, accuracy ≤±1 mm, 24-hour stable mass production capability, and low defect rate with high yield.