Classification And Advantages of Roller Forming Machine

Classification of automatic roller forming machines

According to the different raw materials and types of tile products, automatic roller forming machines are also divided into three main categories.

1. Ceramic glazed tile automatic roller forming machines: these presses are used to produce ceramic tile products made of clay-like clay. After pressing, the products need to be dried, glazed (or not glazed) and then sintered at a temperature of over 1000°C.

2. Cement tile automatic roller forming machine: this kind of roller forming machine is used to produce cement tile products with cement sandstone as raw material. The product only needs to be dried and maintained and then painted.

3. Colour steel roller forming machines: these presses are made from thin steel sheets and the products can be painted after pressing and forming.

The three different types of automatic roller forming machines mentioned above have different structural principles.

1. Automatic ceramic roller forming machines

The automatic roller forming machine used in China's roller forming machine industry was first introduced in Germany, Italy, France and other countries. In 2006, a pottery machine factory successfully developed a localized automatic roller forming machine, compared with imported products, in the details of the part which is more suitable for China's national conditions of improvement. But whether domestic or imported automatic roller forming machines, the basic principle and structure are more or less the same.

This type of ceramic roller forming machine is mainly composed of left and right body, bottom connecting rod, top case cover, sliding seat, hexagonal rotor, belt wheel, gear mechanism, groove wheel mechanism, cam mechanism, lubrication pump, oil circuit system, electric control part and so on. The upper die stamping process of the machine: the motor, through the pulley, drives the input shaft, through the small gear, the large gear, drives the upper shaft, and through a set of cam mechanism drives the sliding seat equipped with the upper die to move up and down to realize the pressing tile. The table is indexed by a gear set mounted on the end of the upper shaft, which drives a pivoting pin gear and pivots a slotted wheel mounted on a hexagonal rotating wheel shaft to achieve indexing and positioning. On the left and right side of the chassis, there is a lubrication pump installed. When the machine is working through, the oil pipe to each friction movement part of the lubricant.

The extruded mud billet, cut into fixed length by the cutting machine, is sent to the roller forming machine by the roller conveyor and sent to the lower mold by the loader according to the prescribed procedure. The pressed out tile billet is absorbed by the vacuum suction cup of the tile unloading machine after the work table is transposed and transposed and placed on the tile tray of the conveying line.

The table of ceramic roller forming machine has six processes, (i.e. Hexagonal wheel) the table is turned over, in addition to a level of mechanical indexing, positioning but also set up a set of precision positioning mechanism, completely ensure that each time the stamping process, the table mold accurate positioning, the installation of the upper die slide is a box structure, slide guide and the upper guide of the body, the contact length is large, each time the upper die stamping, the process has a second stamping on the clay billet That is to say, after the upper die presses the tile billet into place for the first time, the upper die rises 10㎜, so that after the mud billet is fully exhausted, the upper die presses the tile billet into place again before returning to the highest position, thus the die has a long service life and the quality of the pressed products is good.

2. Structure principle of cement tile automatic roller forming machine 

Compared with the ceramic tile automatic roller forming machine mechanism, the structure principle of cement roller forming machine is relatively simple, which mainly consists of hydraulic pump, hydraulic sliding plugs, fixed press tables, movable knocking tables, roller forming machine mold and so on. The working principle is that when the raw material is loaded into the lower mold in the first stage of the process, the hydraulic pump drives the roller forming machine mold to press down automatically, and the cement gravel is filtered out of water under pressure and pressed into a dense and strong cement tile product. In early production of ceramic tile, process has also used such hydraulic machine for pressing, but because of such models in the delivery of billet, mold, take tile automation is difficult to adapt to the clay material blank, very easy to produce deformation, so do not adapt to the ceramic tile industry automation requirements, only in the semi-mechanized ceramic tile can be applied.

3. Color steel tile automatic press tile machine structure principle

The structure principle of the automatic roller forming machine for colored steel tiles is basically the same as that of the automatic roller forming machine for cement tiles. The difference is that the color steel roller forming machine does not need to consider the deformation and maintenance of the products after pressing. Therefore, in principle, its requirements are much simpler, as long as certain pressure is reached. However, compared to the first two types of presses, the size of the product is larger. So the appearance of the machinery and equipment is also a bit larger.

The working table of the color steel roller forming machine has six processes, (i.e. six-sided wheel) the turning of the working table, in addition to a level of mechanical indexing, positioning but also set up a set of positioning mechanisms, completely ensure that each time the stamping process, the accurate positioning of the working table mold, the installation of the upper die slide is a box structure, slide guide and the upper guide of the body, the contact length is large, the upper die of each stamping, the process of the mud billet has a second stamping that the upper After the die is put in place by the previous press, the upper die rises 10㎜, so that the mud billet is fully exhausted, and then the upper die is put in place by the next press before returning to a higher position, thus the die has a long service life and the quality of the pressed products is good. Color steel roller forming machine will be equipped with a set of lubrication systems, when the machine is running, automatically to all bearing, transmission gear mechanism movement guide and other parts of the oil lubrication.

Color steel roller forming machine in the equipment technology is constantly updated, can be divided into three processes. The advantages and disadvantages of each are as follows.

1. Roll forming press tile machine: due to roll pressing production shape single, quality of tile is not high and has gradually faded out of the market.

2.  Extrusion molding color roller forming machine: high yield, fast, but the cost is too high. After forming and then spraying with color spraying machine, the brightness is poor, only the surface layer of color can not be attached to the tile surface alone, but must be mixed in the expensive adhesive can. The Color tile cost is too high.

3. Mold color roller forming machine: at present, the more advanced color tile machine models, most of the machines are using Mitsubishi PLC control system, mainly hand touch screen and digital display of the difference. Moulds are made of special steel, strong and durable long service life. The main machine is equipped with reinforced pressure head and universal pressure plate, which can be easily replaced by different main tile molds and shaped tile molds, suitable for production of various types of cement tiles and road slab tiles.

Equipment installation and commissioning

Before the installation of the above roller forming machines, the foundation of the concrete must be prepared according to the foundation diagram provided by the manufacturer, and the press installation frame (channel steel welded parts) must be placed on the completely cured concrete foundation, the level of the frame must be calibrated, and the foot screws must be grouted for second time, after which the press can be installed.

Equipment operation and precautions

Before using various roller forming machine equipment, check whether the connections are secure, whether the installation bolts and nuts are tightened, and whether the left and right chassis should be sufficiently lubricated with oil to start the machine for trial run, first running empty to carefully observe whether there is vibration, noise, whether the oil window to oil, whether the movement of the parts is coordinated, all normal before installing the mold, when installing the mold, the power must be cut off to prevent the natural fall of the slide seat When installing the mold, the power supply must be cut off to prevent the slide from falling naturally and causing accidents. The upper mold is installed on the bottom surface of the slide, and the appropriate thickness of the mat board is placed to ensure that after the upper and lower molds are combined, the gap around the edge is even, and the distance between the upper and lower molds is equal to the thickness of the required tile. Then the upper mold prevails, the working table is rotated and the remaining five lower molds are installed, all the upper and lower molds are installed before the machine can be driven for roller forming machine.

Working procedure: When starting the machine, the air compressor, the vacuum pump, the extruder, the tile cutting machine, the discharge machine, the roller forming machine, the main machine and the tile tray conveyor are switched on in the opposite order.

Maintenance and care

Those who don't know the structure and performance of this machine and the operation rules shall not start the machine, and the automatic roller forming machine shall not exceed the minimum closing height for work, i.e. the minimum distance from the bottom of the upper sliding box to each surface of work is 290 mm. Pay attention to the height of lubricating oil in the sliding box and both sides of the machine body frequently. The equipment should be wiped frequently to keep it clean and no mud and water should be allowed to accumulate.