Overview of Cable Tray Roll Forming Machines
Cable tray roll forming machines are used to continuously form metal coil into cable trays and other open wiring support systems. This efficient process allows mass production of cable management products in various sizes and configurations to meet different wire support needs.
Key details about cable tray roll formers:
- Produce cable trays, ladder racks, wire mesh trays from coil stock
- Use roll forming process to shape and cut coil as it passes through consecutive die stations
- Output is continuous length of tray that can be cut to desired sizes
- Adjustable forming stations allow producing different tray widths and heights
- Excellent for mass producing cable trays for factories, power plants, data centers
Main Components of a Cable Tray Roll Former
| Component | Description |
|---|---|
| Decoiler | Holds metal coil stock, feeds into roll former line |
| Feeding guides | Straighten and guide coil into roll forming stations |
| Roll forming stations | Progressive die stations that gradually shape and cut coil |
| Cutting device | Shears formed cable tray at set lengths |
| Hoisting device | Lifting system to collect formed trays |
| Control panel | Controls line speed, die position, cut length etc. |
Applications of Cable Tray Roll Forming Machines
Cable tray roll forming systems have various industrial uses:
- Manufacturing standard sizes of perforated or mesh wire cable trays
- Producing ladder type cable trays for power transmission
- Forming wire troughs for cable raceways and wire management
- Creating open runways for electrical conduits in factories
- Mass production of wiring trays for construction industry
- Making cable racks and ladder racks for networks and data centers
Standards for Roll Formed Cable Trays
Most manufacturers follow standards for dimensions, load capacity and finishes:
| Standard | Key Requirements |
|---|---|
| NEMA VE 1 | Protection types, temperature ratings |
| ANSI/EIA/TIA 568 & 569 | Cable capacity, ampacity |
| ANSI/NFPA 70 | National Electrical Code compliance |
| UL, ETL, CSA | Safety certification for US, Canada |
| IEC 61537 | International cable tray standard |
| EN 61537 | European cable tray standard |
| GB/T 3048 | China national standard for cable trays |
Types of Cable Tray Roll Forming Machines
There are two main types of cable tray roll forming lines:
C-Type Roll Formers
- Produce U-shaped cable trays with open top
- Trays have inwardly bent edges for strength
- Allows mounting trays on wall or ceiling
- C-trays provide easy cable access through open top
Ladder Type Roll Formers
- Form ladder style trays with longitudinal wires
- Has better load bearing capacity than C-trays
- Allows attaching trays on floor or ground
- Closed sides provide more protection to cables
| C-Type Trays | Ladder Trays | |
|---|---|---|
| Tray Shape | Show Image | Show Image |
| Load Capacity | Up to 60 kg/m | Up to 120 kg/m |
| Cable Access | Fully open top | Partial open top |
| Protection | Less closed sides | More enclosed sides |
| Applications | Data centers, light duty | Factories, heavy duty |
Other Tray Styles
- Solid bottom trays – Provides enclosed support along entire base
- Ventilated trays – Has openings for airflow and heat dissipation
- Narrow width trays – For smaller cable capacities and spaces
- Extra wide trays – Supports large cable bundles
Key Specifications of Roll Formed Cable Trays
Cable tray roll formers can produce trays in many sizes and specifications:
| Parameter | Typical Values |
|---|---|
| Width | 50mm to 1500mm |
| Height | 25mm to 500mm |
| Metal thickness | 1.2mm to 3mm |
| Tray lengths | 2.5m to 3m standard |
| Load capacity | Up to 120kg/m |
| Finishes | Galvanized, Pre-galvanized, Stainless steel |
| Accessories | Couplers, elbows, risers, reducers |
Tray Width and Height
- Width determines capacity for number of cables
- Common widths are 150mm, 300mm, 450mm, 600mm
- Height provides cable stacking and space
- Heights range from 25mm for a single row to 200mm for multiple rows
Metal Thickness
- Thicker metal coil allows heavier cable loads
- Standard thickness is 1.2mm to 1.5mm
- Heavy duty trays use 2mm to 3mm thickness
Tray Lengths
- Formed in continuous lengths from coil
- Cut into 2.5m to 5m segments for shipping
- Can be field assembled for longer runs
Load Capacity
- Max load capacity from 120 kg/m for heaviest bundles
- Depends on width, height and metal thickness
- Ladder design has higher load rating than C-style
Finishes and Accessories
- Galvanized or pre-galvanized for corrosion resistance
- Stainless steel available for highly corrosive areas
- Accessories like elbows, reducers, risers aid installation
Choosing a Cable Tray Roll Forming Machine
Factors to consider when selecting a cable tray roll former:
Production Output
- Output from 10 – 20 meters per minute
- Larger wattage machines produce faster
- Rollspeed matching coil feed for continuous runs
Forming Capacity
- Number and size of adjustable roll stations
- Capability to produce different tray sizes
- Quick changeover between tray configurations
Type and Size of Coil Stock
- Compatibility with steel, stainless steel, aluminum
- Accepts coils from 250mm to 650mm widths
- Coil thickness up to 3mm
Cut-Off Device
- Precision cut-offs for tray lengths
- Programmable for different sizes
- Clean, square cuts to minimize finishing
Control System
- PLC, HMI for production monitoring
- Preset recipes for different tray settings
- Diagnostics and troubleshooting capabilities
| Specification | Importance |
|---|---|
| Power rating | Determines output speed |
| Number of roll stations | More stations allow complex forms |
| Coil width capacity | Larger coils increase production runs |
| Coil thickness range | Support heavier metal for stronger trays |
| Cut-off accuracy | Reduces post-cutting steps |
| Automated controls | Enables easier size changeovers |
Suppliers of Cable Tray Roll Forming Equipment
There are many manufacturers producing cable tray roll forming lines:
| Company | Location | Product Range |
|---|---|---|
| MBM Engineers | India | 10 – 40 meters/min lines |
| Modern Process Equipment | USA | Upto 60 meters/min capacity |
| Busche Systems | Germany | High-end roll formers |
| Jinpu Machinery | China | Cost-effective systems |
| Annsai Corporation | Taiwan | Standard and custom lines |
Pricing
- Smaller roll formers below ₹15 lakh
- Standard models from ₹40 – 75 lakh
- High speed steel coil lines above ₹1.5 crore
- Stainless steel machines 50% higher
- Custom roll tooling and plant additional
Roll Formed Cable Tray Manufacturing Process
Installation Requirements
- Level concrete or steel base foundation
- Space for decoiler and take-up devices
- Power – up to 150 kW connected load
- Compressed air – 6-8 bar pressure
Machine Operation
- Coil loaded on powered decoiler
- Coil fed into initial forming stations
- Progressive rolling shapes and cuts metal
- Formed tray profiles output continuously
- Cut-off device shears trays at set lengths
- Trays collected on take-up ramp
Production Output
- Line speed from 10 to 60 meters/minute
- Higher speeds with Steel and aluminum
- Stainless steel speed restricted to 30 m/min
Tooling and Changeovers
- Forming stations equipped with hardened roll dies
- Quick die change enables new tray configurations
- Common tools for C-trays and ladder trays
- Average tooling cost ₹10 – 15 lakhs
Maintenance Needs
- Daily – Coil line inspection, lubrication
- Monthly – Drive inspection, belt tension check
- Yearly – Gearbox oil change, electrical safety checks
| Activity | Frequency | Checks |
|---|---|---|
| Line Lubrication | Daily | Roller bearings, slides |
| Tool Wear | Weekly | roll dies, cutters |
| Drive Belts | Monthly | Alignment, tension |
| Oil Changes | Yearly | Gearbox oil replacement |
| Safety | Yearly | Electrical, emergency stops |
Pros and Cons of Roll Formed Cable Trays
Benefits of Roll Formed Trays
- Highly efficient continuous production
- Consistent quality with precision dies
- Low cost for high volume runs
- Fast installation of preformed trays
- Variety of sizes from one machine
- Low maintenance operation
Limitations of Roll Forming
- Initial tooling investment required
- Limited material and thickness range
- Longer lead time for custom sizes
- Lower flexibility vs fabricated trays
- Fixed tray lengths require field assembly
Compared to Fabricated Trays
Roll formed trays contrast with hand fabricated trays:
| Roll Formed Trays | Fabricated Trays | |
|---|---|---|
| Cost | Lower for volume runs | Higher due to manual labor |
| Lead Times | Faster with stock tools | Slower batch production |
| Flexibility | Limited sizes from tooling | Any custom size possible |
| Assemblies | Require couplings | Continuously welded |
| Finishes | Factory applied | More site painting required |
FAQ
What are the most common sizes of roll formed cable trays?
The most popular widths are 150mm, 300mm and 600mm. Heights range from 50mm to 400mm. Metal thickness is typically 1.5mm to 2mm.
What types of metals can be roll formed into cable trays?
Mild steel, stainless steel and aluminum coils are commonly roll formed. Steel allows highest capacities.
What determines the load capacity of a roll formed cable tray?
Tray capacity depends on width, height, material thickness, and design. Typical load ratings range from 60 kg/m to 120 kg/m.
How are roll formed cable trays installed on site?
Trays are cut to length and assembled with couplings. They are mounted on ceiling, walls or floors with support hardware.
How does roll formed cable tray cost compare to custom fabricated trays?
Roll formed trays cost 35-40% less than custom fabricated trays owing to automated production.
What are some accessories used with roll formed cable trays?
Common accessories include inside/outside elbows, tee fittings, risers, reducers, covers, dropouts, and clamping hardware.
Should I choose C-shaped or ladder type trays for my application?
C-type is preferable for light duty ceiling/wall mounting while ladder is better for floor runs needing higher capacity.
What maintenance is required for roll forming lines?
Typical maintenance includes inspecting/replacing forming dies, drive lubrication, belt replacement, and electrical/safety checks.
What factors determine the output speed of a cable tray roll forming machine?
Main factors affecting speed are motor power, number of stands, material type, and thickness. Faster speeds are possible with thinner and lighter metals.