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Rack profiles

DREISTERN

Twin Rollforming machines
P24 and P21

 

Increased productivity with P24 and P21

 

Roller forming blocks

 

Rollforming machines P21.100 and P21.160 use single roller blocks with one pair of rollers:

All rollers are made of the high-quality tempered steel and held by two heavy volumetric tapered roller bearings, used for high concentricity and alignment of the ends of rollers. The height of the upper rollers is adjustable, allowing for reinstallation of the instrument to compensate variations of thickness of a strip or compensate the wear. A rollers drive is a precise worm gear with spur gears. Lubrication is provided by a crankcase. Transfer of the energy from one unit to another is performed through hardened chain connections.

 

 

P24.080 series machine is produced of roller forming blocks, each having four or eight pairs of rollers, held by two conical roller bearings. Top rollers with adjustable hight, are driven by spur gears, lubricated in a crankcase.

The advantage of this machine is an opportunity of quick tool change. Forming blocks can be replaced entirely with rollers and their structure will not be violated. Position pins provide precise positioning. Roller forming blocks are driven by worm gears via a pneumatic connection system with lubrication, performed in a crankcase.

 

The photo:

 

  1. P21 with entry system for cut blanks.
  2. Runout side with section straightening device.
  3. P24.080 for rollforming strip.
  4. Control console and PC with user programme.
  5. Production line with two rollforming machines for automatic forming of control cabinet component panels.
  6. Feed and thickness monitoring systems for cut blanks with two specified thickness.
  7. Twin rollforming machine P21 with positioning motors and absolute angle encoders for automatic adjustment to different material thickness.
  8. Quick-change rollforming unit P24.080 arranged in blocks, each having eight pairs of shafts.
  9. Quick-change tooling facility by exchanging rollforming units.
  10. P24.080 worm drive with pneumatic cylinders for automatic coupling; guide-ways for the width adjustment system with covers.

 

 

 

 

DREISTERN twin rollforming machines are used to manufacture sections for a wide variety of applications:

  • profiled racks
  • refrigerator side panels
  • side and rear panels for steel office furniture
  • metal door frames
  • cable ducting
  • side panels, doors, rear panels and top covers for control cabinets
  • wall and ceiling panels
  • steel doors
  • facade cladding panels
  • roller shutter enclosures
  • profiled sections for building interiors
  • elevator components
  • strip lamp casings
  • cladding panels and top covers for freezers
  • sound-absorbing wall panels
  • wall panels for wet rooms
    etc.

 

 

DREISTERN twin rollforming machines

 

R24. Rollforming blocks with the possibility of quick tool change.

P21. With single rollforming blocks.

 

 

 

Technical characteristics

 

 

 

 

Р24.080

 

Р21.100

 

Р21.125

 

Р21.160

Max. thickness of a blank strip (tensile strength = 400 N/mm2)

 

mm

1,0

1,5

2,0

3,0

Width of the material

 

 

mm

min. 200 - max. 1,000, alternatively - 1,600

Vertical distance between rollers

 

a

mm

120

150

180

220

Vertical stroke adjustment of the upper shaft

 

mm

± 1

± 1

± 1

± 1

Tool width

 

b

mm

125

125

160

200

Horizontal distance between rollers

 

c

mm

200

330

400

500

Roller diameter

 

d

mm

40

50

63

80

Adjustment of the upper roller axis

 

 

mm

± 1,5

± 1,5

± 1,5

± 1,5

Linear speed of roller forming

 

 

m/min

40 (higher speeds - on request)

 

Twin rollforming machines P24 and P21 are designed for simultaneous processing of two edges of sheet metal blanks' strips.

 

Key benefits:

 

  • Four models provide full coverage of a treatment spectrum:
  • Modular design:
  • System version and additional elements are selected in accordance with an order for accurate completion of forming tasks.
    Stepless adjustable working width:
  • The standard variant includes one of two parallel rollforming bases, that can move through the system of regulating spindles. In some cases the unit can be equipped with a system of symmetrical width adjustment. Both systems are completed with a drive with a digital display, allowing for quick change between maximum and minimum values of the desired product. Units can include a function of additional choice of the width, activated from the control panel.
  • High performance:
  • The linear speed of a standard unit is 40 m / min. A drive unit, consisting of two electronically-synchronized direct current motors and gearbox, can be re-equipped for higher working speeds.
    The process of blanks rollforming requires the minimum distance from one element to another, kept by special sensors.
    Economic effect:
  • One continuously working unit can produce even long and complex profile parts with simultaneous processing of longitudinal edges, using high-precision rollforming methods.
  • Tools change:
  • The procedure of standard tools change takes place in accordance with DREISTERN plan of the instrumental setup when upper rollers are adjusted vertically and in accordance with an axle.

Any model can be chosen for different volumes of machining operations:
P24.080, P21.100, P21.125 and P21.160

 

P24 machine provides for easy change of tools by replacing rollforming blocks without any disturbance of the rollers structure. It is easy and cost effective solution with precision maintaining.

 

Criteria for product quality and reliability of the system:

It is extremely important for all edges of blanks and roll strips to be fed into the system accurately for constant excellent quality of roller forming. Such measure provides long-term accuracy of positioning of roller guiding rails. Coarse adjustment of guiding rails is made automatically in case of setting of the treatment width. Precise adjustment is provided by individual tensioning devices with a digital display of positioning.

 

The front guiding system is reinforced with a side units control system, supplying rollers, and current supply control system, used in order to ensure rapid failsafe mode of operation in the process of roller forming, using sheet metal blanks. One guiding rail moves perpendicularly. The guiding rail is fixed directly opposite the edge of a blank pressurized or with a help of an electric motor, when a metal sheet blank is supplied to the table. Thus, the blank is supplied free and fixed under pressure in accordance with the same initial parameters of the edge, regardless of the tolerance width.

The roller supply system consists of drive and damping rollers, pressed against a blank pneumatically. A feed roller drive is a motor with a variable rotation rate, the speed of which is automatically adjusted in accordance with the linear velocity of a roller forming unit.

 

The current supply control system ensures absence of overlapping in case of supply.

DREISTERN has been specializing in the field of design and creation of rollforming plants for four decades. It is a leader in this market segment. Our extensive experience in development of such units allows for solving the most difficult challenges of rollforming.
Today more than 1,000 DREISTERN machines work successfully all over the world. You can also make profit, using the experience and know-how of our experts.

 

P3 Series - High class of profiles forming

 

Areas of application:

  •  
    • Profile forming under the individual orders
    • Production of building materials
    • Production of window shutters, blinds
    • Production of metal door frames
    • Production of storage rack profiles
    • Production of lighting installations profiles
    • Production of electrical construction profiles
    • Production of cable lines
    • Production of slide stops and ball bearings
    • Production of automobile parts
    • Production of composite pipes
    • Production of composite profiles

 

 

P3 series is a market leader in the area of know-how and the best quality technologies:

  •  
    • Optimized metal forming with any characteristics
    • High accuracy of the cross section and highest surface quality
    • The use of special materials doesn't require lubrication or lubrication is required in a minimum amount
    • Minimum strainer-hardening
    • Own department for rollers checking
    • Easy-to-replicate settings to ensure consistent section quality

 

 

Assembled side roller

 

Start-stop system for profile forming

 

Side roller with a connection device

 

Correct block and measuring roller

 

 

Profile forming equipment of the premium quality

 

Hydraulic damping of quickly- changeable cassettes

 

Optimal reconfiguration concepts:

  •  
    • Quickly changeable system to meet all the processing requirements
    • Rapid reconfiguration by manual combination of forming racks
    • Patented automatic connection system for the racks
    • Manual or hydraulic fixing of quickly-changeable cassettes
    • Hydraulic high-speed locknuts

Profile forming roller racks

  •  
    • UN design feature: vertical adjustment of upper shafts
    • UV design feature: vertical adjustment of upper and lower shafts
    • Adjustment of upper and lower shaft in accordance with the axis
    • Powerful tapered roller bearings, mounted in rear racks

Gearboxes:

  •  
    • Cast iron gearbox, worm screws and spur gears
    • Designed to drive upper and lower rollers
    • Different gear ratio
    • Oil bath lubrication (dipping)

 

 
Quickly-changeable cassettes Change of cassettes

 

Manual change of a roller tool

 

Patented high speed automatic connection system

 

Five models of P3 series offer optimum ranges of processing
Modular lines design
Linear speed - up to 160 m / min
Reconfiguration time is significantly reduced due to quickly-changeable cassettes and automatic connection system
Exceptional ratio of cost and performance


 

We can equip our profile forming lines with special devices, depending on your individual needs, and thereby extend the scope of the supplied equipment to cover the entire spectrum of possible operations, performed in the process of usage of profile forming or production lines.

 

 

Roller profile forming racks with universal flexible joints and gearbox

 

UN design:
Vertical adjustment of the upper shaft
   
 

UV design:
Vertical adjustment of upper and lower shafts

 

Production line

Р3.080

Р3.100

Р3.125

Р3.160

Р3.200

Design (see the upper scheme)

UN

UV

UN

UV

UN

UV

UN

UV

UN

UV

Height of the lower shaft, (h) mm

115

115 +10

160

 

160

+15

200

200

+20

250

250

+25

320

320

+30

Vertical stroke (a) from, mm...

                          to, mm

80

185

80

195

85

210

85

225

100

240

100

260

132

350

132

375

170

420

170

450

Axial shaft adjustment, mm

+2,5

+2,5

+2,5

+2,5

+2,5

Horizontal shaft travel, mm

260

330

400

500

630

Working diameter of the shaft, (d), mm

30

40

40

50

50

63

63

80

80

100

Maximum width of a

blank strip:

Base, line B1, mm

Base, line B2, mm

 

 

200

320

 

 

250

400

 

 

320

500

 

 

400

630

 

 

500

800

Maximum thickness

of blank strip, mm

(tensile strength

 

400/mm2)

 

1,5

 

2

 

3

 

4

 

5

Line speed to max,  m/ min

160

160

160

120

80

 

 

Provide us with your requirements for processing and we'll offer the best solutions

© Anton Ohlert 2012
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