Case

Semi-Automatic Light Pole Production Line For 12000mm Poles

One of the press brake application is to bend all kinds of poles, and so press brake factories often receive the clients’ inquiries to produce the press brake for the street light poles and high mast poles bending. Semi-automatic light pole production line is specially designed for poles manufacturing, and below is one of the semi-automatic light pole production line case SC SHENCHONG offered to our client.

Client’s Pole Information

This client has two types of poles want to produce: one is the polygonal poles and another is conical poles.

Polygonal poles (Material: S235)	maximum number of strokes	16
max dimensions
	thickness	6	mm
	length	12000	mm
	diameter (single piece) (minimum)	160	mm
	diameter (single piece) (maximum)	500	mm

Conical poles (Material:S235)
max dimensions
	thickness	4	mm
	length	12000	mm
	diameter (single piece) (minimum)	60	mm
	diameter (single piece) (maximum)	210	mm
	conicity/cone reduction a long the length

min dimensions
	thickness	4	mm
	length	6000	mm
	diameter (single piece) (minimum)	60	mm
	diameter (single piece) (maximum)	135	mm
	conicity/cone reduction a long the length

Light Pole Manufacturing Technology Process

Semi-Automatic Light Pole Production Line Process Flow

Uncoiling
Plate leveling
Plate cutting
Plate oblique shearing machine
Leveling the slitting sheet plate again to reduce the stress.
Stacking of longitudinally cut boards on the unloading device (the process from decoil to stacking the sheet is automatic).
Use crane to transport stacked sheet to the press brake.
Double beam truss loading system to loading the sheet to the press brake front feeding device.
Bending lighting pole
Pole jointing welding machine(tandem press brake unloading poles connect with welding machine).

Main Production Equipment

Decoiling – levelling – cutting line
Slitting Machine
Double beam truss loading system
Tandem press brake
Pole Jointing and welding machine

CNC Cut To Length Line For Light Pole

Model: CTLA6x1600

Automatic type，With four lay type leveling machine+ shearing + 3 blades edge slitting + taper slitting unit.

Features

The raw material is steel coil, and the output is isosceles trapezoidal plate suitable for the size of street light pole
Uncoiling, leveling, length cutting, edge removal, oblique shearing, unlading and stacking in one production line. It is a machine and a process. After the plate shears cross cut, there is no need to drive the crane for loading and unloading, and directly enter the oblique shear process. Reduce the number of operators, labor and improve the production speed.
Full automatic type, sheet length CNC control, sheet quantity CNC control, automatic oblique shear, automatic unloading and automatic stacking system.
The production speed is extremely fast, because the speed is far faster than the subsequent process. Generally, after this process is completed, the operators can work in other processes, which greatly saves working time and reduces production costs.
The operator shall be relaxed and minimize contact with the steel plate, which is safe for personnel.
The shearing machine has the function of overall rotation, which can rotate at a certain angle relative to the center line, so that the cut plate is parallelogram, which is convenient for the oblique shearing machine to obtain isosceles trapezoid plate after oblique shearing, which is suitable for the production of light pole. There is no need for trimming process to reduce sheet metal waste.
Three blade edge cutting device, which can remove the waste edge and cut the middle half at the same time when the sheet width can be used as four poles.
After oblique shearing, the plates in the same direction are stacked separately without sorting. Multiple plates (such as 30 plates) can be directly hoisted to the bending machine, which is safe and saves time.
The optional leveling unit after taper slitting , which can remove the stress caused by the taper cutting and make high-quality light poles.

Technical Parameter And Composed Devices

Technical Parameter

Thickness of material: hot rolled mild steel Max:6mm, Min: 2mm for Q235,Q345, yield strength: 235Mpa, 345Mpa

Max width of steel plate: 1600mm
Weight of steel coil: Max 30 tons
Inner diameter of steel coil: Φ508mm- Φ760mm
Leveling speed: 5- 15m/min
Number of leveling rollers:13, up roller 6, bottom roller 7
Leveling rollers diameter: 132mm
Leveling roller distance: 143mm
Leveling roller material: GCr15
Leveling roller hardness: HRC55-58
Supporing roller device: up and low rollers each 3 units
Supporting roller diameter: 140mm
Length range for scale: 2000～12000mm according requirements
Tolerance of cutting length: less ±2mm (base on 8m length plate)
Main leveling motor power: 37kw, 960RPM
Shearing machine capacity: 6mmx2500mm
Shearing machine rotation angle: 1.5 degree.
double edge and taper Slitting speed: 15 m/min.
Power of the main motor for slitting: 5.5kw
Dolly moving speed: 15m/min. adjustable
Slitting blade material: H13k
Slitting blade diameter: 280mm
taper slitting Pinching roll diameter: 280mm
inner Width of edge slitting unit: 1550mm
inner Width of taper slitting unit: 1800mm
width area for machine: about 7200mm

Detail Of The Device

Steel coil loading dolly car
Hydraulic double-head umbrella type decoiler
Hydraulic pressing and guiding, hydraulic shovel-head device, pinching device
Middle rolling way worktable
Guiding device
Leveling unit: (four lay type)
Rotating typeShearing machine
Pole length supporting table + trolly ,with Automation device :
Plate rising device.
Three blades edge slitting unit.
Pole length supporting table + trolly with Automation device
Plate rising device.
Taper slitting unit
Ball type support table for unloading
Taper plate unloading and stacking automatic system
Electrical system
Hydraulic system
Pneumatic system

Option Items

Option 1: Leveling Unit after taper slitting,

Option 2: Plate offline system

Option 3: Remote diagnosis function.

Option 4 Spare parts

Double Beam Truss Loading System

After slitting and leveling, using a crane to manually lift a stack of sliced boards to the truss station in front of the bending machine.

Workflow：

Vacuum sucker cup of double beam truss loading system grab the plate from the slitting machine roll path.

Load the plate on the automatic front feeding device of the tandem press brake.

Automatic front feeding device of press brake feeds the plate.

Tandem press brake bend the workpiece.

After bending, CNC controlled side unloading device to unload the finished poles.

Finished poles are loading on the roll path of welding machine.

Double beam truss loading system include 2 workstation, each workstation is 2000mm long, and so the double beam truss loading system is 4000mm long.
Double beam truss loading system load weight Max. 1200kg, adopt gear and rack, linear guide as transmission device. Loading part uses servo drive and vacuum sucker cup.

CNC Tandem Press Brake

To meet the client bending requirements, we recommend tandem CNC press brake model: 2-WE67K 600 Tons 6000MM, which total is 1200Tons 12000mm. This machine we design for light poles, material , max. thickness 6mm, Max.length 12000mm, pole diameter 60-500mm.

Special Design For CNC Tandem Press Brake In Semi-Automatic Light Pole Production Line

Automatic front feeding device controlled by CNC

Automatic back feeding device controlled by CNC system

Automatically side unloading device

Automatically suck(including magnetic separation structure, automatically loading structure.

Machine Parameter

Model	2-WEK-600/6000(ESA-S860)
No.	Item	Unit	value
1.	pressure	KN	2×6000
2.	Working table	mm	2×6000
3.	Distance between housing	mm	4800
4.	Throat depth	mm	1250
5.	Ram stroke	mm	300
6.	Approaching speed	mm/s	100
7.	Working speed	mm/s	8-12
8.	Return speed	mm/s	60-100
9.	Axis(13+2)		Y1,Y2,X1,X2,X3,X4+V1 Y3,Y4,X5,X6,X7,X8,C+V2
10.	Y1,Y2,Y3,Y4 parallel tolerance	mm	±0.01
11.	Front feeding stroke	mm	1800
12.	Rear feeding stroke	mm	1250
13.	Daylight	mm	980
14.	Main motor	kw	37×2
15.	Single Machine Overall Dimension (LxWxH)	mm	660037004700
16.	Single Machine Weight	Ton	56

CNC axis specification：

Y1,Y2,Y3,Y4 axis–control cylinder axis, X1,X2,X3,X4,X5,X6,X7,X8 axis –control feeding axis, C–control side unloading axis, V1,V2–cnc control table crowning

Main Performance And Characteristics

The frame consists of fuel tank, tray, support, work table, left and right wall panels and sliders. The structure, high structural strength and large steel degree ensure the structural strength of the frame and adopt vibration to eliminate stress.

The structural parts are rusted by shot blasting and sprayed with anti-rust paint.
Wall panel, slider and workbench are processed by one-time large-scale CNC floor boring and milling machine to ensure the parallelism and verticality of each mounting surface.
The principle of machine synchronization: the application of electro-hydraulic servo proportional valve to ensure synchronization of the two machines, the use of the German company’s electro-hydraulic servo proportional valve, its performance characteristics are high-operating force continuous action of the electromagnet, the friction of the mechanical movement pair A small precision electronic amplifier with fast operating characteristics. A grid is installed at each end of the vertical plate of the workbench, which continuously reflects the stroke position and synchronization error of the slider and sends the two differences into the microcomputer control system to control the electro-hydraulic servo proportional valve to synchronize the twin-cylinders of each single machine. Since the grating scale is not directly mounted on the frame wall panel, but is mounted on a C-shaped frame fixed to the table vertical plate, and the work table is used as a reference point, the slider itself and the frame are under load. The deformation does not affect the measurement and control accuracy of the scale. The two-machine synchronization of the two-machine linkage transmits the mechanical synchronization information into an electric signal to the synchronizing board and the microcomputer through a differential potentiometer installed between the two sliders, and controls the electro-hydraulic servo proportional valve through the amplifying board to make the dual-machine Synchronous action.
The operator can directly perform man-machine dialogue through the computer, displaying in Chinese and English, automatically calculating and adjusting the bending force, optimizing the bending sequence, calculating the length of the workpiece, showing the shape and necessary operation information before and after the workpiece is processed, and Automatic calculation control top dead center, speed change point, image display, full-featured, with programming, jog, pressure, slow recovery control and other functions.

Hydraulic System

It is driven by electro-hydraulic servo valve group imported by German company. It has compact structure, strong sealing performance, high synchronization precision and long service life.
External large-diameter filling valve with high speed and low loss.
Using Sumitomo internal gear high pressure pump can withstand high pressure and low noise.
The cylinder seal adopts the sealing component of Sweden SKF Company, which has low wear and no leakage.
The hydraulic system has overload overflow safety protection.
The cylinder is integrally forged with 45 steel. After rough machining, heat treatment, finishing and fine grinding, the inner wall of the cylinder has both hardness and wear resistance, and high cylindricity precision.
The plunger is integrally forged by 45 steel. After rough machining, heat treatment and fine grinding, the surface is coated with nickel and phosphorus by the most advanced military technology in the country. The cylinder plunger has good self-lubricating property and can greatly improve the service life.
The oil level has a clear and intuitive display.
High-precision guiding system, position measuring system and hydraulic balancing function can meet the needs of full-length machining.
The equipment can work continuously for 16 hours under the rated load, while the hydraulic system has no leakage and the work is stable and the performance is good. The oil temperature can be controlled within the national standard (≤60~70°C).

Electrical Control System

The electrical components comply with international standards, are safe and reliable, have strong anti-interference ability, and the electric control cabinet has heat dissipation function.
It has a movable foot switch for easy operation and an emergency stop function.

The Machine's Anti-Offset Ability

The electro-hydraulic servo system of the machine is a position control system, which dynamically detects the synchronization error of the slider through the grating ruler, and corrects the synchronization error of the slider by the electro-hydraulic servo valve signal given by the numerical control system, so that the slider is completely In the case of partial load, it can always be parallel to the table.

CNC POLE SHUT- WELDING MACHINE

MODEL: HM500/12000

Scope of application: suitable for large length medium size pole longitudinal automatic closing welding, like 5G pole, monopole, highmast pole and normal street light pole.

Features

CNC automatic adjustment, CNC system, with the change of pole diameter, automatically adjust the pressure, automatically adjust the presser foot position, automatically match the feeding speed and position, keep the welding seam always in the closed state, to ensure the smooth welding.
On the basis of the qualification of the previous process, after welding, there is no torsion of the pole weld, and there is no need for personnel to pry and twist the rod at the back of the machine to center the weld.
The driving pole is controlled by frequency conversion, with electric brake stop function to ensure the stability of head and tail welding，this system can weld the pole from small end to bottom end full area and almost no left length out of welding. This way is reduced the manual working of the next process.
The number of clamping roller is 3 sets, the advantage is reduce the roller pressure to the pole surface , and reduce the scratch on the surface . It is suitable for the production of octagonal pole, polygonal pole and conical pole. It can be equal diameter or conical.
The pushing type trolley with motorized fast returning back function, no need operator to push back manually and it reduces the labor intensity of operators.
The rear push trolly with pneumatic clamping device, It’s simple and fast compared with manual clamping.
Submerged arc welding function
The unloading side is roller type, which is convenient for loading and unloading, and is conducive to realize the automation of upstream and downstream materials. The loading and unloading can be on same side to make operator avoid the long-distance movement. The operator only need to work in the position of the host machine, which greatly reduces the labor intensity.
The self-developed oil pressure and control synchronization system reduces the requirements for the pole, making the pole after welding more rounded and less deformed.
Operator: 1 person.
Unloading roller rack，5 sets（suitable for 12，14m pole）
According to the layout of the buyer’s workshop, machines with different working directions can be provided
For the special requirements of customers, machine can be specially designed and manufactured to meet different poles all over the world
Through the camera installed on the machine head, the welding seam is reflected on the screen of main control panel, making the tracking of the welding seam simple and easy, and reducing the labor intensity of the operator for monitoring of the welding.

The Machine Consists Of The Following Parts

Long worktable for trolley moving
Main gantry frame
Trolley drive system
Unloading roller rack，5 sets(suitable for 12，14m pole)
Hydraulic clamping part(Including clamping rollers, suitable for medium size pole)
Submerged arc welding system, with wire feeding system
Flux recovery system
Hydraulic system
Control system
Camera, welding seam monitoring system. Clamping roller, in accordance with customer’s pole requirements. With 1 set suitable for monopole High mast, 5G pole mold. with

1 set suitable for normal street light poles, minimum diameter of 60mm (round poles and conical pole)
1 set suitable for normal street light poles, minimum diameter of 60mm (octagonal pole)
A set of rear clamping devices suitable for normal street light poles . (Includes a small tool, suitable for poles with very short length, such as 1~2 meters long arm)

Street light pole loading and unloading system (optional)
Networked production data system
Remote diagnosis function
Oneyear spare parts

Semi-Automatic Light Pole Production Line Production Efficiency

By adopting above semi-automatic light pole production line for 12000mm poles, the client achieves excellent production efficiency result.

Cut to length line + slitting machine for normal street pole manufacturing: 200~250 pieces/ 8hours.
Press brake: normal street pole and high mast pole: 80-160 pieces/ 8hours.
Shut pole welding machine: normal street pole : about 50 pieces/8 hours.

Conclusion

Semi-automatic light pole production line includes slitting machine, cut to length line, plate shearing machine, automatic loading machine, tandem press brake, frame welding machine. Different factory layout and different poles manufacturing requirement should use different production line proposal. Welcome to contact with us for more light pole production line proposals.

Related Article:

High Mast Light Poles Industry