The success of your business depends on the quality of the end product of your profiling system. Control systems can be implemented in various parts of the entire production line, not just in the roll forming machine.
Creating complex, fully automated profiling operations also requires you to control the process to ensure consistent results. Automating the profiling process, from coil handling to packaging, requires the same attention to detail. At many stages of the profiling process, efficiency can help ensure consistent part quality and increase uptime. Choosing the right tool to control the accuracy of this line is also critical.
The speed at which metal enters the front end of the roll forming machine has a significant impact on the efficiency of the roll forming system. Batteries are a great way to keep your roller running. The bale exiting the decoiler enters the end shear welding machine and then into the accumulator before being fed to the next in-line process. When the entire bale is fed into the accumulator, the next bale can be spliced with a shear welder without stopping the bale formation process. After welding a new coil, new material is fed into the accumulator. Traditionally the tube mill was the only process that used a battery, but now it can be added to any roll forming system.
To make sure the process is working correctly, it is important to test the material. Even if the reel is operated by an operator, an independent check with an automated feedback system is useful.
It is also possible to control the outer diameter of the roll and make a decision based on the material remaining at the end of the roll. For example, if a particular product requires a 40-foot piece and has 39 feet of material left at the end of the roll, it cannot be used for that piece. If left unattended, you may be left with 39 feet of waste. However, you can make usable shorter parts with an automated monitoring system. Therefore, coil monitoring increases the flexibility of the automated process.
The monitoring system can also be used to check material thickness and width and compare them to programmed part data. It signals the machine to stop if the wrong material thickness or width is used.
Integration of equipment in the middle of the production line is another possibility. Adding other processes to the line, such as high frequency welding systems and spot welding systems, helps improve the efficiency of the production line. As with any welding system, feedback mechanisms can be used to ensure accurate welding.
Welds at the end of a roll can be tracked and controlled, and parts can be recycled. The system also monitors the appearance of the part, i.e. checks that the ends are properly aligned before starting welding for accurate bead placement.
For example, a test can be integrated to check the dimensional accuracy of punched holes or to determine if the number of punched holes is correct.
The speed at which metal enters the front end of the roll forming machine has a significant impact on the efficiency of the roll forming system. Batteries are a great way to keep your roller running.
The choice between using a vision system or a laser inspection system will depend on the complexity of the perforation pattern, hole configuration, material throughput, and any other information available.
In some cases, the material needs to be bent to size on the line. However, during processing, if the bend radius of the part is too large or too small, the software takes the feedback and automatically corrects the settings on the bending block to correct the discrepancy.
What happens to your finished product after the profiling process is completed? Various material handling systems can be integrated at the end of the roll forming line to improve efficiency. Samco offers a variety of options including strapping machines, stackers and pick and place devices.
Products can be packaged or shrink wrapped for packaging. The protective film can be placed on the top or bottom of the package. A pallet can be added to the bottom of the packages so that they can be easily moved using robotic lifters, which then stack the packages in a safe pyramid for transport.
Of course, care must be taken to ensure that any damaged or unsuitable parts do not end up at the end of the line with the good parts. Built-in inspection systems effectively remove damaged or unsuitable parts from the final package if necessary.
The technology can be used to measure the profile of a part, the location of holes, the presence of holes and the length of a part, as well as other measurements. If a part does not meet specifications, it can be disposed of appropriately.
While monitoring technology can be a valuable addition to any profiling system, upgrading an already installed system is not necessarily an easy task. If you want to add feedback mechanisms and online process systems to existing systems, it is important to consider your workshop space and how it can best suit you. Remember that in many cases, automation requires more space than manual work.
The latest and greatest automated materials handling systems can make life easier for any manufacturer. Automation has become a necessity not only to manage large production without increasing labor costs, but also to create a safer working environment. With the right automation set up in the input, in line and packaging, the efficiency of your profiling system can be greatly improved.
Jaswinder Bhatti is Vice President of Application Development at Samco Machinery, 351 Passmore Ave., Toronto, Ontario. M1V 3N8, 416-285-0691, www.samco-machinery.com.
There are many packaging options such as strapping and shrink wrap that can be added to a roll forming line. Care must be taken to ensure that any damaged or unsuitable parts are not packaged at the end of the line with quality parts. Built-in inspection systems efficiently remove parts from final packaging.
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Post time: Jun-15-2023