THE HAYES Rapid Change Stud Mill

Bringing a new dimension in versatility and cost effectiveness to the metal framing industry

SPECIFICATIONS

UNCOILER	ROLLFORMER
2500kg Cantilevered uncoiler, with screw linkage type expansion, disc brake and powered drive. INFEED GUIDES 5 sets in total, of crosswise adjustable entry guides, using heat treated rollers on screw adjustable slides. LUBRICATION Both top and bottom lubrication tanks, with engineer felt wiper pads are fitted. ENTRY DRIVE ROLLS 2 sets are provided, either side of the straightening rolls for accurate strip feeding. STRAIGHTENING ROLLS A set of 2 over 3 rolls, assist in eliminating bow and camber problems. The rolls have a simple single screw vertical adjustment. MEASURING ROLLS A dedicated station for strip length measuring, using a quadrature rotary encoder, ensures accurate lengths. SHEAR A straight knived, cut off shear, with electromechanical actuation is fitted. This shear provides a high speed quality cut. Blades are hardened and ground D2 tool steel. CONTROL SYSTEM The line is fitted with a multiple order entry, programmable controller for both length and batch functions, and is housed within a free standing operators control console. The console incorporates all manual and automatic machine functions, along with the variable speed motor controller. GUARDING This machine is comprehensively guarded to meet "Occupational Health & Safety Standards". RUNOUT BENCH 6 Metres of roller top conveyor, are included.	Section 1, Indentation Forming Rollers 2 Stations are provided for forming of web indentations, following by a set of indentation straightening rollers. The indentation rollers are mounted on a common carriage, for simple setting by screw adjusters and gauges. Section 2, Lip Forming Rollers 5 Stations are provided for forming of lips, followed by lip straightening rollers. The lip rollers are all mounted on a common carriage, for simple setting by screw adjusters and gauges. Section 3, Embossing Rollers 1 Set of embossing rotary dies, are fitted for flanges "glue-facing". The dies can be simply slid in or out, to suit. Section 4, Flanges Forming Section 12 Stations are provided for forming of the flange to web corner. These are fitted with unique overforming rolls for accurate and simple squaring of the corner. A final straightening head is fitted prior to the feed out rollers, for bow and camber control. These rollers are all mounted on a common carriage for simple setting by screw adjusters and gauges. TOOLING All form tooling is manufactured from 4140 high tensile steel, is precision machined, polished and nitride hardened, to 62 HRC. DRIVE The drive to all forming rollers, is split on 3 gearboxes longitudinally, and, via splined shafts and heavy duty chain on both sides of this machine. A variable speed 18.5kw electric motor provides drive to the gearboxes, for a rolling speed of 50 metres per minute up to 1.2mm thickness, and 30 metres per minute for 1.6mm thickness.

A versatile, simple to use, and affordable solution for metal framing production.

Infinite Sizing The ability to form both standard and custom size studs, nogs or tracks. In fact, any size within the machine's parameters. Rapid Size Changing In less than 5 minutes, a size change can be effected with minimal operator skill, eliminating spacers, shims and guesswork required on conventional mills. Automatic Gauging From 0.5mm to 1.6mm in thickness, with NO settings or adjustments required. The auto-gauging accounts for both the horizontal and vertical tooling clearances. Flange Embossing Embossing for glue facing can be added or removed, simply by sliding in or out the rotary die. Pre-Cut Shearing Coil feed up and rewind becomes much simpler, with minimal scrap, and unique straightening heads eliminate common bow, twist, camber and flare conditions. High Speed Operation A combination of rapid size changing and forming speeds of 50 metres per minute, will nett production levels superior to conventional roll-forming operations.

Options

Twin Head Turret Uncoiler
Designed to speed up the coil changing, giving even greater nett production capabilities and extending the maximum coil size up to 4000kg.

Coil Loading Car
Designed for use with either forklift or crane loading, this car simplifies coil changing, and provides a safer working environment.

Tool Steel Tooling
For extreme duty applications, the 4140 tooling can be replaced with D2 tool steel, extending tooling life significantly.

Stacking, Bundling and Strapping
A semi-automated bundling system is available to maximise productivity while minimizing labour requirements.

Product Identification
Available as either inkjet marking, or stick on labels, product identification includes client ID, product type and specification, bar coding, and sort codes. This option requires a PC based control system upgrade, and is inclusive of office downloading software.

Short Length Capability
As a pre-cut machine, the normal minimum length is 1800mm. This can be reduced to 200mm by providing a part cut shear, so as to produce a row of short lengths strung together. They are simply separated after forming by snapping the parts from the length.

Automatic Size Changing
Each of the carriage size setting leadscrews, can be fitted with servo-drives, enabling size changes to be carried out from the control console.

Service Hole Punching
Available as either straight punched hole or as flared hole punching, and is designed to integrate with the machine controller the unit is designed to punch up to 6 holes simultaneously so as not to affect the machines productivity.

Mitre-Cutting
A mitre cutting press is available, to integrate within the line. A separate dieset is required for each product size and mitre angle.