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Automatic Crash Beam Roll Forming Machine

Automatic Crash Beam Roll Forming Machine

Automatic Crash Beam Roll Forming Machine

Product Overview

This production line is specifically designed for manufacturing automotive impact beams and is suitable for the continuous forming of high-strength steel (≤ 980 MPa). The process flow includes uncoiling, leveling, punching, roll forming, welding, arc bending and fixed-length cutting, ensuring the strength and accuracy of the profiles.
The equipment adopts a modular design. The uncoiling, leveling, punching and hydraulic systems can be shared, reducing investment and maintenance costs. Combined with PLC automatic control, the entire line operates stably and efficiently, meeting the strict requirements of the automotive manufacturing industry for safety components.

Configuration Options

Basic

Standard

Advanced

Economical and practical, meeting basic needs

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Balanced performance, stable and reliable

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High-speed, high-efficiency, intelligent and durable

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 MaterialOrdinary carbon steel ≤ 600 MPa High-strength steel ≤ 780 MPa Ultra-high strength steel with a yield strength of ≤ 980 MPa, suitable for automotive-grade steel applications 
 DecoilerManual hydraulic unwinder ≤ 5T Hydraulic unwinding machine ≤ 10T, with pressure arm Fully automatic hydraulic unwinding machine ≤ 15T, equipped with variable frequency control and material arc detection 
LevelingStandard 7-roller leveling 11-roller precision leveling CNC-controlled leveling, supporting rapid material change and thickness compensation 
 PunchingConventional hydraulic punching Servo feeding + hydraulic punching, ±2.0mm accuracy Full servo punching, ±0.5mm accuracy, rapid mold replacement 
 Roll FormingGear + Chain Hybrid Transmission Full gearbox transmission, frame-type frame High-precision gearbox transmission, with the entire machine processed by CNC and key slots machined. 
BendingFixed mold curved arc Hydraulic arc bending, manual adjustment CNC hydraulic arc bending, automatic angle setting 
 Welding UnitNo (requires external welding) Welding interface reserved outside the line Automatic welding within the line, supporting argon arc/laser welding 
 CuttingHydraulic fixed-length cutting, with an accuracy of ±2mm Hydraulic fly saw cutting, with an accuracy of ±1.5mm Servo tracking cut-off, with an accuracy of ±1.0mm 
 Control SystemPLC + Button Control Mitsubishi PLC + touch screen, with encoder for fixed measurement Mitsubishi/Siemens PLC + touch screen, remote diagnosis, data acquisition 
 Speed5-8 m/min8-12 m/min12-15 m/min
 Operators3 to 4 people2 to 3 people2 people, in favor of automated loading and unloading

Performance Comparison

 Roll Forming Machine Other SuppliersEffect
 Machine FrameArched structure welding + CNC gantry milling for precision finishing Panel-type or ordinary welded frame Our company offers superior stability and accuracy. The conventional solution only meets basic requirements. 
 TransmissionHybrid transmission of gearbox and chain Single chain drive The hybrid transmission has better stability and longer lifespan, while the conventional chain is prone to wear. 
Roller MaterialGCr15 undergoes quenching treatment, resulting in high wear resistance. 45# steel with hard chrome plating The conventional rollers can meet the requirements, but there is a significant gap in the mass production of high-strength steel. 
 PunchingHydraulic punching, supporting rapid mold change Blanking operation on a punch press Hydraulic system is more flexible and the mold change speed is faster; the press machine still has advantages when handling large tonnage. 
 CuttingHydraulic pre-cutting, Cr12MoV blade quenching treatment Hydraulic post cutting, 45# steel blade Our product has a longer lifespan and higher precision. The regular blades show significant differences when cutting through high-strength steel. 
 AccuracyLength accuracy: ±1.0mm; Cutting accuracy: ±1.5mm ±2.0mmHigher precision, reducing subsequent adjustments 
 Speed15–20 m/min10–15 m/minThe speed is slightly faster, meeting the requirements for large-scale orders. 
 AutomationPLC + servo fully automatic control, supporting multiple fixed-length settings Basic PLC, with more manual intervention The automation level is higher, reducing the need for manual operations, but the cost investment is slightly larger. 
EnergyApproximately 45 kW 40–50 kWThe energy consumption varies little and is within a reasonable range overall. 
 Maintenanceonce or twice a yearaveraging 3 to 5 times per yearHigher stability and lower downtime rate

Video

Automatic Crash Beam Roll Forming Machine

Product photo

  • Equipment assembly line
  • Equipment assembly line
  • Equipment assembly line
Hydraulic unwinding machine
The system adopts an automatic feeding mechanism and a hydraulic tensioning structure, combined with a hydraulic trolley, making the operation very convenient. It also features pneumatic braking and variable frequency speed control, ensuring stable unwinding.
Hydraulic shearing and welding machine
It is used for trimming the irregular ends of steel coils and automatically welding them, enabling continuous production without the need for downtime. It features a hydraulic shearing mechanism and rapid welding technology, with efficient operation and suitability for feeding from different directions.
Leveling machine
The structure adopts an upper and lower multi-roller design. The roller shafts are treated with quenching and hard chromium plating to ensure high precision and wear resistance. Front and rear are equipped with guiding rollers and pressing devices, which effectively control the sheet movement and ensure stable feeding.
Servo Punching Mechanism
The NC servo feeding system is adopted, which is suitable for plates with a thickness of ≤ 2mm. The combination of high-speed feeding and high-precision positioning ensures stable and reliable punching dimensions.
Directional structure
The main machine entrance adopts a roller-type guide on both the left and right sides to ensure the accuracy of the sheet material feeding position. The guide position can be manually adjusted via a screw rod, and it can be independently adjusted left and right to guarantee the forming accuracy.
Rapid mold change forming system
Equipped with 2 sets of modular forming systems, it enables quick switching between different plate types, reducing downtime and enhancing production flexibility.
Platform-type laser welding
Using a 6000W dual-purpose continuous/impulse laser, the water cooling system ensures stable operation. The welding speed can reach 0-8m/min, ensuring a strong weld seam and efficient production.
Hydraulic shearing mechanism
It adopts a four-column hydraulic shearing structure, which also has a punching function. The material loss per single shearing operation is approximately 6mm. The knife holder is made of high-quality carbon steel and welded, and then undergoes quenching + CNC precision processing. The knife material is Cr12MoV, which is quenched to HRC58-62, ensuring high strength and wear-resistant lifespan.
Hydraulic system
It adopts a single-loop hydraulic structure, equipped with a vane pump and a 7.5KW power unit, and is equipped with a Yuken 24V safety electromagnetic valve. The system is cooled by air, ensuring stable and reliable operation and meeting the requirements of continuous production.

Finished product example

Car body panel
Automobile frame equipment
Automobile frame
Car pillar equipment
Car frame
Impact absorbing beam
Impact absorbing beam
Service Support
On-sale
After-sales
On-sale

Senior engineers provide on-demand, phased training and on-site machine inspections. Efficient supply chain integration and excellent value for money.

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After-sales

Professional pre-shipment inspection services, lifetime technical support; engineers dispatched to your site for on-site installation, commissioning, and operational training to accelerate production and operations; spare parts marketplace with instant replenishment and express shipping to ensure production and operational continuity.

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On-sale
Engineer Training Appointment
Efficient meeting communication, focused on answering questions and resolving issues. Utilizing a "theoretical explanation + hands-on demonstration + group practice" model to accurately convey knowledge.
On-site machine inspection at the factory
On-site machine inspection at the factory to personally test equipment performance and accuracy. Conducted by a team of professional engineers and in collaboration with a third-party testing institution.
Recommended high-quality supporting suppliers
We have established a high-quality supply chain resource pool based on more than ten years of industry experience and have built an intelligent supplier matching system.
After-sales
Professional device inspection service
A team of senior engineers equipped with professional testing tools provides 24/7 online support and a 2-hour response time for urgent tickets.
Engineer dispatch on-site
A team of senior engineers with over 10 years of industry experience. Implementation of a three-stage training system comprising theory, practical application, and assessment. A special "on-the-job training" component is included, with engineers fully participating in the first week of trial production.
Accessories Store
Build your own full-category accessories mall. Rely on an intelligent warehousing system to achieve 24-hour lightning-fast delivery. Through visual logistics tracking and factory-based safety stock solutions.
Qualification Certificate

The company has obtained ISO 9001:2008 quality management system certification. The over 30 series and thousands of specifications of products produced have passed the national CCC certification and CE certification issued by TUV.

Forming machine MD main certificate
Forming machine MD main certificate
Forming machine EMC main certificate
Forming machine EMC main certificate
Vertical stacking MD main certificate
Vertical stacking MD main certificate
Vertical stacking EMC main certificate
Vertical stacking EMC main certificate
Open Book MD Main Certificate
Open Book MD Main Certificate
Open Book EMC Master Certificate
Open Book EMC Master Certificate
Two-way stacking MD main certificate
Two-way stacking MD main certificate
Two-way stacking EMC main certificate
Two-way stacking EMC main certificate
FAQ
01 /
Payment Method

We usually adopt the payment method of 30% advance payment + 60% payment before shipment + 10% payment after installation and commissioning are completed to ensure the rights and interests of both parties.

02 /
Delivery Cycle

The delivery time for standard equipment is generally 45 to 60 days. If personalized customization is involved, the specific time will be adjusted appropriately according to the complexity of the plan.

03 /
Installation and Commissioning

We provide detailed installation instructions and operation materials. Customers can complete the basic installation according to the instructions. If professional engineers are needed for on-site services, our team members hold multiple national visas and can directly go to the customer's factory for debugging and training. The related travel and service costs will be borne by the customer.

04 /
Warranty and Services

The equipment comes with a 1-year warranty and lifetime technical support by default. If the customer agrees to authorize the project for case presentation, we can extend the warranty period by an additional 1 year.

05 /
Operators and Skill Requirements

Each device is equipped with detailed operation instructions. Generally, 2-3 workers can complete the production process. The operation interface is simple. The default language is English (other languages can be optionally selected), and basic training is provided to ensure that the operators can start working quickly.

06 /
Equipment maintenance and servicing

We offer comprehensive maintenance manuals and schedules, covering daily inspections, maintenance of key components, and long-term maintenance. This ensures that customers can operate in accordance with the standards, and the maintenance procedures are clear and easy to understand, facilitating on-site implementation.