Crash Barrier Roll Forming Machine in India

Machine Description

A Crash Barrier Roll Forming Machine is specifically designed to produce crash barriers, also known as guardrails or highway guardrails. These barriers are crucial for road safety, preventing vehicles from straying off roads or crossing into opposite lanes. The machine forms high-quality steel profiles that meet safety and durability standards for use in highways, bridges, and other infrastructure projects. Crash barrier profiles are typically made in "W" and "Thrie" beam shapes, conforming to stringent safety and quality guidelines globally.

Key Specifications

1. Roller Material: High-grade steel, typically GCr15 or Cr12MOV, which is heat-treated for durability.
2. Forming Stations: 18-24 forming stations, depending on profile specifications.
3. Punching and Notching System: Servo-controlled hydraulic system for precise punching and notching at required intervals.
4. Material Thickness: 2-4 mm steel, usually hot-dip galvanized or coated for corrosion resistance.
5. Material Width: Accommodates 300-500 mm coil width.
6. Coil Inner Diameter: Compatible with 508 mm and 610 mm coil ID.
7. Machine Speed: Typically 10-15 m/min (with punching) and up to 25 m/min (without punching).
8. Hydraulic Cutting System: Precision hydraulic cutters for clean, accurate cutting.
9. PLC Control System: Automated control system (Siemens or Mitsubishi) for machine programming and accuracy.
10. Drive Motor: High-powered motor (usually around 15-30 kW) with AC frequency converter for smooth operation.
11. Safety Guards and Enclosures: Full safety enclosure with emergency stop features for operator protection.
12. Output Conveyor: Automated stacking system for finished profiles.

Profile Description

• Materials: Hot-dip galvanized steel or coated steel, 2-4 mm thick.
• Profile Types: W-beam and Thrie-beam profiles, common in crash barrier applications.
• Popular Sizes: Standard 310 mm for W-beam and 506 mm for Thrie-beam.
• Material Gauge: 12 to 14 gauge for strength and durability.
• Market Size: Widely used in road construction and highway safety industries worldwide.
• Industries: Road construction, infrastructure, and government projects.
• Countries: The machine's output is popular in countries with extensive road networks like the USA, India, China, the EU, and the Middle East.

Optional Extras

• Coil Handling System: Coil car or decoiler with hydraulic capabilities.
• Stackers: Automated stacker for efficient material handling.
• Remote PLC Systems: For remote operation and diagnostics.
• Hydraulic Press System: Option for deep punching applications.
• Uncoiler/Recoiler: Helps with managing the input and output of coils during production.

Setup and Installation Process

1. Location Preparation: Secure, level surface with ample room for material feeding and output.
2. Electrical and Power Requirements: Ensure compatibility with local power supply and connect to a stable power source.
3. Roller Adjustment: Set up rollers based on the specific profile dimensions.
4. Programming the PLC: Input required parameters, including profile length, punching locations, and speed settings.
5. Trial Run: Perform test runs to confirm alignment, punching accuracy, and cutting precision.

Maintenance Requirements

• Lubrication: Regularly lubricate rollers and bearings to reduce wear.
• Cleaning: Keep the machine clean, especially the rollers and conveyor, to prevent buildup.
• Hydraulic System Check: Inspect hydraulic oils and components to prevent leaks.
• Electrical Systems: Check wiring and PLC functions periodically.
• Roller Alignment: Realign rollers as needed to maintain profile accuracy.

Question and Answer Section

1. What types of crash barrier profiles can this machine produce?
The machine is designed to produce standard W-beam and Thrie-beam profiles, the most commonly used crash barrier types globally. These profiles are essential for highway and road safety applications.

2. What materials can be used in the machine?
Typically, hot-dip galvanized steel or coated steel is used, with a thickness range of 2-4 mm, providing corrosion resistance and strength for crash barriers.

3. How does the punching system work in this machine?
The machine is equipped with a servo-controlled hydraulic punching system that precisely punches holes at specific intervals, ensuring accurate alignment for easy installation.

4. What is the maximum speed of this machine?
The machine generally operates at 10-15 meters per minute with punching and can reach up to 25 meters per minute without punching, depending on the material type and thickness.

5. Is the machine compatible with different power supplies?
Yes, the machine can be customized to operate on various power supplies, such as 220V, 380V, or 440V, depending on the country’s specifications.

6. How does the PLC system work?
The PLC (Programmable Logic Controller) is used to control machine functions, including material feeding, punching, and cutting, and ensures precision through automation, minimizing human error.

7. Can the machine be operated remotely?
Yes, with optional remote PLC systems, operators can manage machine settings and monitor performance from a distance, which enhances safety and efficiency in production lines.

8. What are the safety features included in the machine?
The machine is equipped with full safety guards and enclosures to protect operators. Emergency stop buttons are strategically placed for immediate shutdown in case of issues.

9. What maintenance does the machine require?
Regular maintenance includes lubrication of moving parts, cleaning the rollers and conveyor, checking the hydraulic system, and verifying the alignment of rollers to ensure accurate profiling.

10. How can this machine help my business reduce costs?
The machine automates crash barrier production, reducing labor costs and increasing efficiency. Its high speed and accuracy decrease material waste, and the ability to produce standard crash barrier profiles ensures compliance with industry standards.