Trailer & Railcar Tanks Manufacturing
Tanks manufactured for road and rail transportation are designed to be the lightest possible to increase the payload. The direct consequence is the use of thinner and high-quality plates in carbon steel or stainless steel with high tensile strength.
Therefore, the production target is to:
- reduce to the very minimum the ovality tolerance of the rolled shell and to ensure the same roundness is then obtained in the heads spun on the flanging machine.
- decrease manual fitting
- ensure the repeatability of the components.
To obtain the above production objectives, it is important to invest in a tank manufacturing line composed of:
- CNC controlled 4-roll plate rolls equipped with:
Plate handling and supports systems which are fundamental accessories to increase productivity.- Lateral supports with multiple joints, guide the plate towards the central support, holding it up during the initial rolling step, leaving free the main overhead crane for other jobs inside the workshop.
- The cross central support prevents the re-closing of rolled ferrules under their own weight in addition to avoid the plate-overlap during the second end pre-bending. It has 2 orthogonal controlled axis in order to bear the weight of poli-cylindrical (double D), oval, elliptical and cylindrical ferrules with high diameter thickness ratio. The interpolation between the 2 axis to handle elliptical or poli-cylindrical ferrules is managed by the CNC system. The cross central ferrule support is an essential device to produce poli-cylindrical ferrules in an automatic single step process.
- Modern feeding tables are designed to automate the plate feeding. While on one side the machine is rolling, on the other side the feeding table is automatically placing the next metal sheet in the exact same position than the previous one, for immediate introduction and transportation, resulting in valuable time saving. A smart solution for high volumes that ensures operators safety.
- CNC dishing press with automated manipulator.
- CNC flanging machine.
It is also essential to obtain the repeatability of the tank manufacturing line, and this is the reason why FACCIN GROUP has developed CNC software that guarantees excellent results.
The success of the CNC is also the result of a complete redesign of the hydraulic circuit including the choice of its components and a PLC software ready to receive the CNC input.
Consequently, at Faccin Group we have implemented the use of high-quality market-standard technical solutions of hydraulic components and various designs to ensure that all axis of the machines can be operated simultaneously.
The company has also taken into deep consideration the matter of energy and processes efficiency to reduce the energy consumption and carbon footprint.
In this regard, the hydraulic system for the Faccin CNC controlled plate rolls has been updated with the latest components. Highly precise sensors have been included to monitor the hydraulic valves and thus the signal to correct the required amount of oil for each axis action. This solution, already tested in many machines, is the result of 10 years of development and has allowed FACCIN Group to offer the industry a product that is at least 20/25% more efficient than the standard hydraulic packs available in the market.
This hydraulic system is an exclusive development achieved by Faccin in close collaboration with a major German manufacturer and it is available only upon request.
Regarding the head forming line, The Group has updated the design of the hydraulic system to reach a higher level of efficiency and has rebuilt the PLC software as well to achieve the total control of the forming process to reduce the plate thinning which is extremely important to keep control on the tank weight.
This updated control of the forming process also helps the action of the die impact on the plate targeting, giving better uniformity with a simultaneous absolute position control.
The typical size of a dishing press to produce road tank ends is 300 ton reaching up to 400 ton when the range is extended to railcar tanks. Should it be the case of intense production, a 600 ton press is the ideal choice to increase the number of blanks/round plates being pressed together in a single stack.
The final step is the flanging operation, which can be done in cold or warm forming, as in the case of aluminum.
The Group’s range of flanging machines is the widest in the market and includes all types of machine configurations to make dished heads with or without the center hole. Additionally, the option of tiltable upper beam, a very useful feature to have when flanging wide diameter long cones, is available.
The height of the flanging machine is generally extended to facilitate the loading and unloading of the maximum head diameter and for flanging cones with vertical axis on a specially dedicated tool, working on a rotary platform.
The flanging machines designed by Faccin Group, feature an electric-powered main-rotation system to reduce the energy consumption and to extend the rpms of the main shaft. Obtaining the highest speed achievable, is fundamental for the final cosmetic pass to make the outer surface of the dished head, very smooth. Experienced manufacturers in the trailer tank industry know how important this is since after painting the surface, defects will be revealed.
Thanks to the Group’s solution the need of a costly plastering is eliminated. Indeed, plastering has also a negative environmental impact on the tank construction.
In summary, Faccin Group’s updated forming systems reduce the environmental impact of the forming process, by cutting unnecessary time and ultimately improving the product quality.
For more information www.faccingroup.com
Article by Rino Boldrini
Development of New Processes & Energy Efficient Equipment
