MECHANISED DEVICE

a) CU Stud and track light frame forming machine MF200

MF200 machine is a factory automatic and manual machine that been used for
many years. It’s a machine that moved and operate to simplify and speed up work
with great accuracy and less error and also maintain the high-performance level of the
output.This machine is a machine that combine several equipment to make it work as
a forming machine.The machine components used are Hydraulic, De-coiler Leveling
Device, Roll Forming System, Online Printer, Punching & Cutting Device, PLC
Control System, Hydraulic Station, Run out table. All the components are needed in
one set.It’s a machine that can be seen in the factory as it’s a big size machine.Below
shows the flow chart of the production machine.

Flow Chart

The flow chart is showing below :

Auto De-coiler→Leveling Device→Roll Forming →System→Punching & Cutting
Device →Run out table

Figure 1 : CU Stud and track light frame forming machine MF200

Function & Operation of the MF200 machine

MF200 is a multi-sizes light steel frame machine that can support up to 5 stories
building, different from LG10 is with bigger profile size and more suitable for high
rise buildings with heavy snow, strong wind and also it is with a very significant
advantage for the floor joist system, which is with higher bearing capacity and easy to
assembly.This machine can make stud & track, floor joists and stairs. Technology
Parameters used about the machine are the about 5.0T for the weight.The total
dimension with un-coiler, run out table is (length)13m x (width)1.2m x (height)1.6m.

The operation flow of the casting machine starts with the decoiler.The De-coiler
type is hydraulic auto de-coiler.Secondly the guiding device is used to guide and
fasten the raw material raw material into roll forming station steadily. The raw
material max capacity that can be processed are Max 3.0T.

Figure 2 : Rolling Forming System

Then the after the raw material steadily ready, it go to the Rolling Forming
System. It hat produce shapes of different sizes and material thicknesses using the
same rolls. Variations in size are achieved by making the distances between the rolls
variable by manual adjustment or computerized controls, allowing for rapid
changeover. These specialized mills are prevalent in the light gauge framing industry
where metal studs and tracks of standardized profiles and thicknesses are used. The
MaSpeed of forming about 35m/min and the roller stands can hold 15 rolling stands.It
typically begins with a large coil of sheet metal, between 1 inch (2.5 cm) and 20
inches (51 cm). in width, and 0.004 inches (0.10 mm) and 0.125 inches (3.2 mm)
thick, supported on an uncoiler. The strip is fed through an entry guide to properly
align the material as it passes through the rolls of the mill, each set of rolls forming a
bend until the material reaches its desired shape. Roll sets are typically mounted one
over the other on a pair of horizontal parallel shafts supported by a stands. Side rolls
and cluster rolls may also be used to provide greater precision and flexibility and to
limit stresses on the material. The shaped strips can be cut to length ahead of a roll
forming mill, between mills, or at the end of the roll forming line.
 Figure 3 : Roller stand

Thirdly, after the machine had done rolling the shafts of rollers are tooled by
grinding machine for two times to ensure the precisionof final product.The Bearing
used are NTN brand from Japan. The frame of machine are designed as square tube
shape and thickness of frame is 30mm in order to make sure the machine is capable to
bear all accessories of this machine. It also used flare control rollers that flare device
is made of two group rollers with manual adjusting device. The Full-automatic can
change sizes by PC control system.The Machine is able to change purlin size within 1
minutes, so the size purlin needed to produce for floor joist,stud and track and stairds
can be set by PC system.

Figure 4 : Machine Frame

Finally, the hydraulic punching and hydraulic cutting are to

trimming hydraulic press edge cutting hydraulic press and edge cutting hydraulic.The
Hydraulic punching will puch the holes needed with the criteria. The punching dies
are made from Cr12 and driven by hydraulic station. All the holes locations will able
to set by PC panel. After punching the machine wil used the hydraulic cutting will
shear the raw material automatically, driving raw material out of roll forming system.
The shearing type are hydraulic shearing with guillotine cutting. The cutting material
are Cr12 also. Then after all the process done all the send it to the 4 meter material
receiving table, with a C stud & Track stacking platform.
 Figure 4 : Run out table

Recommendation on fully programmed machine

Figure 5 : PC control system LG-R300.

For this time being, the safety guard are used to covers the whole machine to
ensure worker’s within PC control system LG-R300. The control system MF 20 is
able to program production CNC by inputing Dahe’sTXT or CSV format and connect
with machine directly. It can control machine auto-running and running status
dynamically, including punching, cutting and size changing. All the size will be kept
the same because of the PLC control system & components are be used. The machine
will control the quantity & punching length & cutting length automatically.The
machine will be stopped while it is punching and cutting automatily with length
measures and quantity counting (precision +-0.5mm).
Figure 6 : PLC Control System & Components

Figure 7 : Profile image and application

b) LIGHT GAUGE STEEL

Light gauge steel is a tool in which the steel frame wall system, truss system and
floor joist system are made. In the construction of wall structures and roofing systems,
light gauge steel is most sometimes used.

In the production planning of light gauge steel, there are many phases. BD Vertex
design software is the first step. Construction design by Vertex BD design software is
designed for production software to design NC output data. The LGS HBS
Manufacturing Process is second. This move starts with, the data from the Vertex BD
NC output for input design. LGS 'own self-developed HBS development system will
run processing machines and enhance frame configurations. Other than that HBS
Machine. During part manufacturing, PLC panels may describe each operation. As a
consequence of a trigger in the manufacturing process, it may replicate a product that
fails. Lastly assembly. The multiple components have inkjet encoding free of charge.
Drawing from the Vertex BD programme should obey the assembly.

Traditional wastes material between each pieces

Next, there are many significant characteristics to note about light gauge steel.
The first is to conserve materials. With the output code of Vertex software, there is
always an inevitable material waste of 45-50mm when it comes to one part with
chamfer cut or with flat cut, such wastage can amazingly reach 1.7-2.1%. Based on
above calculation, a yearly production of 5000 Ton approximate will generate 100
tons wastes. However, in view of this situation, HBS LGS production system has
made a serials optimization, which minimizes the wastage to a minimum. The
accompanying diagram illustrates the disparity in material waste using various
approaches. One uses standard systems and the other uses units of HBS.
 HBS Equipment controlled the waste to a minimum

No jamming on the machine is the second feature. In many cases, when it comes
to large door and windows there is a special design on the header, Crip stud or Jack
stud. To ensure the structure intensity, the designer would normally design the column
parts into groups. Such structure are rather easy to jam the machine. It might take at
least 1 hours to debug machine with a skill full operator. The roller space has to be
readjusted after the debug. Otherwise it may bring several damages like Shafter
breaking, roller crushing and so on. Sheet are wasted again during the machine
readjusting. HBS has invested capital & resource in improving LGS equipment
especially on the roll forming station & shearing station to make sure machine won’t
jammed while producing special columns. The following diagram provides
representations of column sections in the group design.

Diagram 1 Diagram 2
MACHANISED DEVICE

The diagram below shown the specification of the device.

Operation process:

1. De-coiler

Decoiling is the process by which the steel coil is unwinded and sliced to length.
It goes through a levelling system that flexes the steel through a series of rolls as the
coil is unwound from the parent coil in such a manner that the material is extended to
its yield point to reset the stresses induced during processing at the steel mill. This
results in a fully flat steel sheet that is ideal for manufacturing' lights out. Our
comprehensive process expertise means

that, every time, the expectations of the customers are fulfilled. We can manufacture
steel sheet packs if desired, whereby each sheet is vertically dropped one on top of the
other by means of an electro-magnetic stacking device, thereby preventing the risk of
damaging the sheet surface.
2. Leveling device

Leveling is accomplished by bending a metal strip precisely back and forth as it

moves through a series of offset rolls of limited diameter. On the entry and departure
of hydraulic levellers, the distance between the rolls is set separately. We tightly nest
the entrance rolls to level a metal strip, causing the metal to move through drastic
angles to remove "memory" caused by stuck inner pressures. We refer to "The
Plunge'M." as the entrance area. This is where the content is made - or the memory is
deleted from the strip. The Plunge’M has 3 stages: removing internal stresses, the
stretch and lastly is reset the memory.

3. Punching device

Punching is a shaping method that uses a punch press to push an instrument,

called a punch, to produce a hole by shearing through the workpiece. Punching is
applicable to a broad range of sheet-form materials, including sheet metal, paper,
vulcanised fibre, and certain types of sheet plastic. Often the punch moves through a
die during the job. In the operation, a scrap slug from the hole is deposited into the
die. This slug may be recycled and reused or destroyed based on the substance being
punctured. Punching is also the cheapest way to build holes in low to large output
quantities of sheet materials. Where a specially shaped punch is used from a sheet of
material to make several functional sections, the procedure is known as blanking. The
job is often punched when warm in metal forging applications, and this is called hot
punching. Slugging is the punching phase in which the punch is stopped as soon as
the metal fracturing is complete, and metal is not withdrawn but kept in the cavity.
The burnished field, rollover, and die break will show the hole walls and must always
be further processed. The slug from the hole falls into some kind of jar through the die
to either dispose of the slug or recycle it.

4. Rolling forming system

Roll forming, also spelled roll-forming or roll-making, is a method of rolling that

involves continuous bending into a desired cross-section of a long strip of sheet metal
(typically coiled steel). Sets of rolls placed on consecutive stands pass along the strip,
each set completing only an incremental part of the bend before the desired cross-
section (profile) is achieved. Roll shaping is suitable for manufacturing long distances
and large amounts of constant-profile materials. Roll forming machines are available
which, using the same rolls, create forms of various sizes and material thicknesses. By
having the differences between the rolls variable by manual adjustment or
computerised controllers, changes in scale are obtained, allowing for quick
changeover. In the light gauge framing industry, where metal studs and tracks with
uniform profiles and thicknesses are used, these advanced mills are popular.

The lines may be set up for cutting a part to length using a pre-cut die where a single
blank passes through the roll mill, or a post-cut die where the profile is cut off during
the process of roll shaping. By punching in a roll forming line, features may be
inserted in a hole, notch, embossment, or shear form. These component characteristics
may be performed in a pre-punch application (before roll formation begins), a mid-
line punching application (in the middle of a roll forming line/process) or a post-
punching application (after roll forming is done).
5. Cutting device

The Cut To Length line is a highly effective assembly line for metal processing for
cutting flat sheet metal from metal coils. Unwind, level, cut to length and blank the
metal coils. RISHBIN supply maximum range of cut to length line according to
client's special requirement by merging separate part. For consumers, each CTL line
is planned and constructed differently, it is personalised designed and built, it is taken
into consideration when selecting a correct CTL line for such details such as
manufacturing power, running speed, content thickness and distance, etc. Prior to
release to our valued consumers, specification and regular tests are strictly conducted
on our product. Hot rolled steel, cold rolled steel, galvanised steel, pre-painted steel,
high tensile steel, stainless steel, aluminium, copper, alloys are available raw
materials for cutting to the length side. Auto cut to length RISHBIN light gauge
machines are optimised for speed and ease of use and can achieve higher line speeds
without material slippage being encountered. Light gauge lines are also capable of
handling surface critical content without labelling. The Cut-To-Length Line and the
Blanking Line would make it easy for you to operate, decrease costs and raise
earnings. Start-stop shears, flying shears, revolving shears or continuous direct feed
may be supplied to the cut to length system for sale on Rishbin. High-precision four,
five and six-height, computer-controlled levellers. There may be added edge
trimming.

6. Out-let table

This is the last operation process for light gauge sheet. This occurs after the process of
cutting. The cut sheet is then moved to the float sheet stacker where it is packed on a
pallet and then transferred for processing to a semi-automatic packing line.
Machine Components

De-coiler Type Auto Hydraulic de-coiler

Weight capacity: 3.0T

Punching All punching dies are made from

Cr12Mov. Holes parameter is able to
set by computer.
Hole Type can be customized.

Rolling Forming System Main motor type: servo motor

Speed of forming: 48m/min
Roller: 12 groups of rollers.
Shaft & Frame: Shafts of rollers are
tooled by grinding machine for two
times to ensure the precision of final
product.
shafts. Material of main shaft : 40Cr.
Machine frame Material of frame: A3

Hydraulic Cutting Cutting material: Cr12MoV

Online printer Online inkjet printing system.

Marks and Item Number are available
to be printed on the flange side for easy
assembling pieces to pieces.
Out-let Table 4 meter Product support frame
C stud to the stack platform

Safety Guard Safety Guard covers the whole

machine to ensure worker’s safe.

Computer system. Using software -Design Software Part

Control panel Control the quantity &

punching length & cutting
length automatically
The Machine will be stopped
while it is punching and cutting
Automatic Length measures
and quantity counting
(precision +- 1mm)
Design Software Part – Vertex
BD Pro