The complete Shelf Fabrication System application is actually two (2) systems in one line.
The following application is a complete coil feed system to manufacture a wide variety of shelves from 18 gauge galvanized mild steel. The system is designed to pre-notch and punch the strip, rollform the two (2) side profiles in a single pass through operation, endform both ends and toggle lock all four (4) corners in a fully automatic line system.
The shelves are produced in five (5) basic widths from 8” to 30” wide in lengths from 13” to 52” long. Part lengths within the same coil strip width can be run in any quantity or order without additional set-ups or scrap loss.
The Rollformer features our special variable head concept that varies the form rolls and part profile with a leadscrew / handwheel setting in less than a minute. The pre-notch and punch press dies are also set-up with leadscrew settings with micrometer readouts for a quick change application. All the line settings can be changed in approximately five to ten minutes to accommodate coil and part width variables.
The complete application is actually two (2) systems in one line. Coil cut-to-length and automatic shelf production line. It was estimated that automating the shelf would eliminate a lot of labor, handling and scrap loss but all their production would require only about 30% of the capacity of the system. We widened the decoiler, straighten and shear cut-off on the system allowing them to also use this as a blanking line. The inline Rollformer is set-up on tracks and can be shuttled in and out of line with the coil strip feed. Using the same programmable feed controls and drives the system is converted to a coil feed blanking line in a matter of minutes.
The programmable micro process length batch controller will sequence the feed and cycle the pre-notch and post cut-off presses. The rollformed shelves will then be sequenced through a series of programmed tangent form operations to form a double return flange on the lead and trail ends of the shelves. The tangent former tooling is sectioned and spaced to accommodate the five (5) width variables eliminating any set-ups or changeovers. It’s also programmed to sense the overall part length and can accommodate a variety or combination of feed lengths in a random order without any changeover, down time or scrap loss.
The inline corner toggle lock system is designed to toggle or button lock the trail end of one (1) part as it locks the lead end of another. This also allows you to run a variety of feed length combinations eliminating any set-up.
The design of this combination shelving, blanking line is another example of how Custom Rollform builds special systems best suited to match the customer’s needs and requirements. We offer a variety of multiple pre-tooled rollform applications to run several profiles or products of the same system. Variations in material thickness and material types can usually be run on the same Rollformer and we work with a variety of special pre-painted, polished or laminated materials.
The new redesigned shelf has proven to be lighter and stronger by adding darts in the Endformer and toggle locking the corners together.