Warehouse Shelf Upright Rack Roll Forming Machine
Warehouse shelf upright rack roll forming machines fabricate specific configurations out of long strips of metal, usually coiled steel. These machines are energy efficient and adjustable, and provide a precise finished part with minimal material waste.
Structural racking systems are best applied to fast-paced environments with heavy loads where frequent lift truck impact is a concern. These systems are constructed using high-quality, thick low-gauge steel components and assembled by bolting them together.
The Basics of a Basic Roll Forming Machine
The basic roll forming process converts flat sheet metal into an engineered shape. It uses consecutive sets of mated rolls that each nudge the material into a different position to gradually bend it into a shape with a contoured cross-sectional profile. The geometric possibilities are broad and can include enclosed shapes, and the profile depth can range from less than 1 inch to more than 20 inches.
A feed coil of metal is loaded into pallet rack roll forming machine the decoiler, and the material is pulled through a pre-press application that can reduce or taper its lead end for smooth feeding into the machine’s station rollers. These rollers, which may be powered by hydraulic or mechanical action, are the heart of the machine and shape the metal as it passes through each station.
Before the metal leaves the forming station, it may be through a punch application that can punch holes or slots into the metal for structural purposes. It may also be slit, or have its edges folded back and welded together to make it more functional. These types of applications are called “pre-punching” and can reduce the weight of the finished metal or allow for easier welding.
The final shaped part can be cut to length before it leaves the machine, or it can be trimmed on site, with a saw, for example. The resulting parts can then be used in a variety of applications, including storage racks, steel drawers and automotive frames.
CAD software translates drawings and specifications into a program that controls automated tools/machines. Compared to traditional manufacturing methods, CAD/CAM systems significantly reduce the amount of time between designing and producing products. These systems do this by substituting hand-made jigs with computerized programs that directly define machine functions.
CAM software allows users to create 3D models and then translate those designs into physical parts. It also eliminates the need for engineers to design and test a part before it can be produced because they can simply input that data into automated machines to get immediate feedback.
Warehouse Shelf Upright Rack Roll Forming Machines are used to produce warehouse rack uprights, cross beams, support columns and deckings for pallet storage in logistic industries. This equipment uses a high-quality forming and cutting process to make a wide range of warehouse rack components. These include galvanized and CS stainless steel, which are popular choices for the storage of heavy goods.
Unlike structural racking systems that use heavier, thicker higher-gauge steel components, roll formed racking systems are composed of thinner lower-gauge metals and rely on shape for strength. This makes them easier to assemble and disassemble, which is a major advantage for facilities with limited floor space and slow-paced operations. You can find these types of racking systems in retail and 3PL warehouses, as well as cold environment warehouses.
Programmable Logic Controllers
The hardware and software that complete the automation of industrial electromechanical processes are called programmable logic controllers. They use microprocessors to handle control functions and have a built-in programming language for simplifying the type of coding pallet rack roll forming machine required to create the logic structures that monitor device or machinery performance. They are ruggedized to withstand the rigors of industrial environments and have extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact.
PLCs provide a variety of input and output devices to support various machine operations, from monitoring operating temperatures to recording run-time data to generating alarms when conditions are outside of an operator’s preset parameters. They also have a number of communications and network ports for connecting to other machines, computers, or networks. Some types have a built-in power supply that eliminates the need for a separate voltage conversion circuit and reduces the amount of space needed in the cabinet for wiring connections.
Shelf and Pallet Rack Roll Forming Machines are used to produce warehouse racking components such as teardrop uprights, cross beams, diagonal bracing and shelf decking. Formtek offers integrated systems from multiple brands including B&K, Dahlstrom, Hill Engineering, Lockformer Custom Machinery, Tishken and Winpro that combine a combination of press brake forming, notching, welding and roll forming in order to streamline manufacturing processes and reduce labor costs.
Laser or TIG Welding
Laser welding uses an intense beam of light to join materials. With TIG welding, the welder creates an arc between the base metal and non-consumable tungsten electrode. The arc heats the base metal to the point of vaporization, where a molten weld pool forms. Thin filler metal is carefully fed into the pool to complete the weld. The process produces a slag-free weld with the same corrosion resistance as the original metal.
The quality of the weld depends on how much energy is transferred from the laser spot to the material being welded. A lower power density results in a calm weld puddle and is best used for cosmetic welds such as outside corners of boxes or signs. When the power density increases, the laser welds deeper into the material for a stronger keyhole weld.
A laser machine can be equipped with several types of nozzles to deliver the type of gas that’s needed for the weld. More sophisticated machines offer the option to set a timer for pre-gas and post-gas emission-to clear the area of oxygen before starting the weld, and to help with cooling afterward.