1. Core Conclusion (One-Sentence Summary)
The structural upgrades of a high-speed cable tray roll forming machine mainly focus on the drive system, forming structure, punching system, cutting system, electrical control system, and full-line automation coordination.
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Standard machine speed: 5–8 m/min
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High-speed machine: 15–25 m/min (up to 30 m/min)
2. Key Structural Comparison
| Item | Standard Machine | High-Speed Machine | Upgrade Advantage |
|---|---|---|---|
| Drive System | Chain transmission | Gearbox + universal shaft drive | Strong torque, stable speed |
| Machine Frame | Welded steel frame | Cast iron stand structure | Anti-vibration, high precision |
| Shaft Diameter | 60–70 mm | 80–100 mm solid shafts | Suitable for high-speed load |
| Punching | Stop punching | Flying punching (non-stop) | True continuous high speed |
| Cutting | Stop hydraulic cutting | Flying cutting / tracking cutting | No stop, high accuracy |
| Control System | Standard PLC | Servo + synchronous PLC system | Full speed synchronization |
| Automation | Semi-automatic | Fully automatic + auto stacking | Save labor |
| Line Coordination | Single machine logic | Full line synchronized design | No jamming, no material crash |
3. Key Structural Upgrade Explanations
1️⃣ Drive System Upgrade (Most Critical)
Standard Machine:
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Chain drive
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Problems at high speed:
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Vibration
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Chain jumping
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Loud noise
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Easy wear and break
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High-Speed Machine:
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Gearbox drive + universal shaft
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Advantages:
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Much stronger torque
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Very stable transmission
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Suitable for long-time continuous high-speed operation
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This is one of the most expensive and most important structures of a high-speed machine.
2️⃣ Forming Frame Upgrade (Guarantees Precision)
Standard Frame:
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Welded steel plate structure
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Easy vibration at high speed → profile deformation
High-Speed Frame:
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Cast iron stand structure
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Advantages:
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Strong rigidity
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No deformation
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Long-term stable precision
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3️⃣ Punching System Upgrade (Key for True High Speed)
Standard Machine:
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Stop punching
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Punch → stop → run → punch again
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Production speed is limited
High-Speed Machine:
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Flying punching / Servo tracking punching
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Punching and forming work simultaneously
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No need to stop the line
This determines whether the machine is ordinary capacity or real high-speed production.
4️⃣ Cutting System Upgrade
Standard Machine:
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Stop cutting
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Machine stops for every cut
High-Speed Machine:
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Flying cutting / tracking cutting system
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Cutting during running
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Length accuracy: ±1 mm
5️⃣ Electrical Control System Upgrade (High-Speed Brain)
Standard Machine:
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Normal PLC + frequency inverter
High-Speed Machine:
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PLC + Servo motors + synchronous control system
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Perfect synchronization of:
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Punching
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Forming
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Cutting
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Discharging
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All systems run at high speed without disorder.
6️⃣ Automation Level Upgrade (Labor Saving)
| Type | Workers Required |
|---|---|
| Standard Machine | 3–4 workers |
| High-Speed Automatic Line | 1–2 workers only |
Optional automation:
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Automatic receiving
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Automatic flipping
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Automatic stacking
