Shipbuilding Use J16 Reinforced Angle Steel Rib Stiffener Plate Straightening Machine

A.      Function, Strong Points and Application of Wuxi JACK J Series Reinforced Angle Stiffener Plate Straightening Machine:

1.       Applicable Background of Angle Ribbed Plate Straightening Machine:

1)      In Shipbuilding/ Bridge/ Port Machinery industries, ribbed plates are often used to strengthen mechanical body of finished construction;

2)       These ribbed plates are fabricated from several pieces (Usually 3~6 pieces) of Angle Steels onto a piece of large carbon steel plate;

3)      After being fabricated, Angle Steels on stiffening plates easily bulge up, making surface of the entire plate unit uneven;

2.       Function of Angle Rib Plate Straightening Machine:

1)      Wuxi JACK developed J models Angle Stiffener Plate Straightening Machine is for levelling the above-mentioned upturned Angle Steels on plate units:

2) A piece of 30 meter long 3 meter width reinforced plates unit being flatten from Wuxi JACK J16 Reinforced Angle Rib Plate Straightening Machine at customer workshop: (Fig.1)

3.      Advantages of Wuxi JACK Angle Stiffening Plate Straightening Machine:

1)       Highly Automation:  The entire operation can be managed with easy job. Except workpieces loading in and out, all the remaining jobs are processed automatically, including straightening ram displacement control;

2)      Precise Position of Straightening Rollers in Angle Ribbed Plate Straightening Machine:

a)      Position of fabricated Angle Steels onto plate differs, within certain variation range of 450~ 600mm;

b)      Correspondingly, during running of the Angle Stiffening Plate Straightening Machine, straightening units need to be moved laterally, to aim on the Angle Steels precisely;

c)      Such horizontal movement displacement is managed with closed loop control, and detected with encoders;

3)       Intuitive Working Process: Operator just need to key in control parameters at initiation of work period:

Advanced technology HMI (Human machine interface) monitor in Angle Ribbed Plate Straightening Machine: (Fig.2)

4.       Related Equipment with Reinforced Angle Stiffener Plate Straightening Machine:

1) ASM Series Angle Steel Straightening Machine: For straightening longitudinal deflection on single piece of Angle Steel;

2) RH Series Edge Rounding Machine: For deburring and removing sharp angles on edges of ribbed plate unit.

B.       Applicable Workpieces for J16 Reinforced Angle Rib Plate Straightening Machine:

1.       Number of Angle Steels on Workpieces of Angle Stiffener Plate Straightening Machine:

1)       It can be from 1 piece to several pieces, such as 5 pieces:

2)       A piece of 5 Angle Stiffener Plate levelled from Wuxi JACK J16 Angle Ribbed Plate Straightening Machine: (Fig.3)

3)       Meanwhile, there are 3 sets of straightening units in Angle Rib Plate Straightening Machine. So, the straightening units need to be adjusted on its lateral positions several times, to finish the leveling task;

2.       Width of Reinforced Plate Unit in Angle Stiffening Plate Straightening Machine:

1)       Min. width request on the reinforced plate unit is 800mm;

2)       Max. width of reinforced plate that can be fit into working zone of the Stiffener Plate Straightening Machine is 3000mm;

3.      Thickness Range of Stiffening Plate Unit: From 6mm to 16mm. This is model “J16” got from;

4.      Length Range of Stiffener Plate Unit: There is no restriction on the shortest and longest size. So long as it can be laid onto input and output conveyors of the Rib Plate Straightening Machine;

5.       Intervals of Angle Steel on the Ribbed Plate Unit: As mentioned previously, this adjustable interval of fabricated Angle Steels on the reinforced plate unit is from 450mm to 600mm;

6.       Material of Rib Plate Unit: Most majority conditions, customer apply carbon steel ribbed plate unit. Of course, it can be any other available sheet metal, such as 16Mn/ Stainless Steel/ Alloy..., etc.

C.       Operation on J16 Reinforced Angle Stiffening Plate Straightening Machine:

All the main actions of the Angle Stiffener Plate Straightening Machine are controlled with advanced technique software and hardware integrated operating system in HMI station:

1.      Primary Interface in J16 Angle Stiffener Plate Straightening Machine: (Fig.4)

1)       All the main working motions of the machine are managed in this interface;

2)       Such as: POWER ON/ OFF; Oil Pump Start ON/ OFF; Power Indicating Lamp; Straightening Units 1~3 Start ON/ OFF, etc.

2.      Straightening Unit Interface in J16 Angle Rib Plate Straightening Machine: (Fig.5)

1)       In this interface page, lateral movement and position of each straightening unit is controlled;

2)       Operator just need to key in corresponding process control parameters;

3.       Hydraulic Station Interface in Angle Ribbed Plate Straightening Machine: (Fig.6)

Purpose: Hydraulic system gives heavy force and reliable power on straightening process:

D.     Structure and Main Units of J16 Reinforced Angle Ribbed Plate Straightening Machine:

1.       Constructure of J16 Angle Rib Plate Straightening Machine:

1)       Running Site: This custom design Stiffener Plate Straightening Machine is deployed in large scale Shipbuilding production line;

2)       It has a set of strong base fixed installed mechanical main frame, with input and output conveyors;

3)       During operation, workpieces move through the entire working zone of the Stiffening Plate Straightening Machine, and being levelled simultaneously;

4)       Operating site of Wuxi JACK J16 Angle Stiffening Plate Straightening Machine: (Fig.7)

2.      Main Units in J16 Angle Stiffening Plate Straightening Machine:

1)       Mechanical base bed, with grounding style workpiece holding platform;

2)       Primary driving motor reducer;

3)       4 pieces of round cross upright columns;

4)       Overhead platform, for laying on control board and hydraulic pump station of the Rib Plate Straightening Machine;

5)       3 sets of top and bottom installed coupled straightening unit;

6)       Input and output conveyors, its length can be designated by customer;

7)       Electric control and operating system;

8)      Hydraulic drive system and station.

Main frame central unit of Wuxi JACK J16 Reinforced Angle Rib Plate Straightening Machine at customer factory: (Fig.8)

E.       Technical Features of J16 Reinforced Angle Stiffener Plate Straightening Machine:

1.       3 Sets of Straightening Units in the Angle Rib Plate Straightening Machine:

1)       Working Mode: The 3 sets of straightening units can either work as a team, or individually;

2)       Its horizontal movement is driven with motor reducer, detected with encoder, protected with electric limit switches and mechanical hard stops;

3)      The critical action of downward stroke straightening is powered with hydraulic oil cylinders, and operated with 2 stages of fast down and inching adjustment, in the Angle Stiffening Plate Straightening Machine;

4)       Each set of straightening unit has 1 piece of top and bottom assembled straightening roller, always move in phase, and have co-linear central axis;

5)       3 sets of straightening units in Angle Ribbed Plate Straightening Machine: (Fig.9)

2.       Holding and Transporting Workpieces into and Through Angle Ribbed Plate Straightening Machine:

1)      Quantity: There are 1 piece of supporting roller installed at front and rear side of mechanical main frame respectively, for holding on and guiding workpieces moving forward through the Stiffener Plate Straightening Machine;

2)       Drive: These 2 supporting rollers are hydraulic drive, with 40mm elevating stroke. The 2 rollers can be elevated separately;

3)       Transmission: The 2 supporting rollers are integrated with bottom straightening roller by means of chain sprocket coupler;

4)       Vertical Positions: Its bottom position can be 20mm lower than conveyors of the Rib Plate Straightening Machine; Top position 20mm higher than that of conveyors;

View on the 2 pieces of supporting rollers in Wuxi JACK customer installed J16 Reinforced Angle Stiffener Plate Straightening Machine: (Fig.10)

F.       Technical Parameters of J16 Reinforced Angle Rib Plate Straightening Machine:

No.	Parameters	Specification	Note
1	Suitable Ribbed Plate Width	800-3000 mm
2	Suitable Ribbed Plate Thickness	6-16 mm
3	Angle Steels Intervals	450-600 mm
4	Straightening Velocity	6000 mm/min
5	Angle Steel Specification	80-120 mm	Side Length
6	Min. Interval of Angle Steels  Straightened simultaneously	680 mm	When less than 680mm, straightening should be performed 2 times
7	Height of Input and Output Conveyors Rollers	600 mm
8	Elevating Stroke of Front and Rear Supporting Rollers	40 mm
9	Straightening Units Quantity	3 Sets	Each unit includes 1 piece of top and bottom roller each
10	Lateral Movement of Straightening Rollers	Zero position set with proximity switch	Displacement detected with encoder
11	Rated Hydraulic Pressure	25 MPa
12	Straightening Oil Cylinder Model	D125/d70-S200
13	Primary Drive Motor Power of Reinforced Angle Stiffener Plate Straightening Machine	15 kW
14	Hydraulic Pump Station Power	5.5 kW
15	Electricity Power	AC380V/ 50Hz/ 3P