Grotnes is at the forefront of delivering innovative solutions in metal forming, and our oil housing bead roller station is a first-class example of excellence in the field. This high-speed roll forming machine is designed to create flawless inward beads on filter bodies and integrate seamlessly with a manufacturer’s existing conveyor systems.
An Eye for Modern Improvements
Grotnes staff can examine outdated aspects of customers’ operations and implement custom-tailored, modern improvements. In a practical application of our expertise, Grotnes was recently invited to upgrade a client’s older metal-forming machinery for oil filter production. We rose to the occasion and replaced complex mechanical systems with a modern, electric servo solution, enhancing speed, reliability and ease of maintenance.
Equipment Overview and Process Flow for Oil Filter Production
The bead roller station is capable of handling cylindrical tubes in a horizontal orientation, transitioning them smoothly from the singulator to the bead roller mandrel. Our actuator is key to this process, ensuring each tube is aligned by pressing the dome against the mandrel, setting the stage for the bead forming process. Once the bead is formed, the tube is cut and sent back to the singulator, ready to continue on the conveyor.
Our system operates on servo-controlled axes, which allow for fine-tuning of depth and velocity as dictated by the part’s specifications.
The bead roller station is comprised of several components:
Base Frame: The foundation of the machine, designed for stability and durability.
Infeed Chute: Engineered to align with your existing chute system.
Spindle with Drive System: The powerhouse of the roller system.
Roller Feed System: Facilitates the smooth feeding of parts through the machine.
Tool Set: A comprehensive set that includes all necessary components for forming.
Loading and Ejection Devices: Automated for seamless operation.
Shell Trim Device with Ring Stripper: Equipped with magnetized nests for consistent part handling.
Scrap Ring Chute: Strategically designed for easy maintenance access.
Control System: Utilizing Allen Bradley technology for a range of control options.
Operator-Free Use and Cycle Time
Designed for autonomy, the Grotnes bead roller station operates with minimal human intervention, requiring only a supervisor to oversee the process and manage alarms. The cycle runs through a consistent action of feeding, singularizing, positioning, forming, cutting and ejecting, all in a harmonious workflow. Part to part, cycle times typically vary between 2 and 4 seconds.
Changeover Efficiency
Our system is designed for quick changeover, facilitated by both HMI/recipe-driven and manual adjustments. In the proposal stage, we provide estimated times for changeovers based of customer specifications to ensure they can plan for the most efficient use of the system.
How Grotnes Can Help
Grotnes is the single source for manufacturers seeking custom-tailored metal-forming solutions, such as our bead roller station. Our commitment to innovation, coupled with more than 125 years of experience, positions us as your ideal partner in advancing your production capabilities.
We want to hear about your next manufacturing challenge or head-scratcher. Together, we’ll elevate your process’s efficiency, precision and reliability. Connect with Grotnes today for a consultation and learn more about our comprehensive suite of machines!
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