Cable Tray Making Machine

Cable tray making machines are used to manufacture cable trays – an important component in electrical installations and industrial buildings for routing cables and wires safely. This comprehensive guide provides a detailed overview of cable tray making machine technology, working principles, types of machines available, manufacturing process, raw materials required, applications where used, cost considerations, tips for choosing suppliers, installation and maintenance procedures, and more.

What is a Cable Tray Making Machine?

A cable tray making machine, also known as a cable tray roll former, is an automated machine that forms metal coil strips into cable tray sections through a series of progressive dies and bending operations. The formed cable tray acts as a support system to safely carry electrical cables, wires, pneumatic tubing etc. in various indoor and outdoor structures.

Cable trays come in many sizes and designs – ladder type, ventilated channel type, solid channel type, wire mesh type etc. The cable tray making machine has customized dies and tooling that shape the metal coil into the desired tray configurations with great precision.

TypeDescription
Ladder TypeLongitudinal side rails with transverse rungs resembling a ladder
Ventilated ChannelU-shaped channel with ventilation slots/holes for heat dissipation
Solid ChannelEnclosed U-shaped channel with no ventilation
Wire MeshTrays made of wire mesh grids welded together
Center SpineSpine inside channel for extra support
Cable Tray Making Machine
Cable Tray Making Machine 12

Working Principle of Cable Tray Making Machines

The working principle involves uncoiling the raw metal strip, guiding it through a series of progressing forming stations with rollers and dies to bend, cut and punch holes, finally cutting finished cable tray pieces to length.

StepOperation Description
FeedingMetal coil loaded, strip fed into machine through straightening rollers
FormingForming rollers progressively bend metal into tray shape
PunchingDies punch ventilation holes if required
NotchingCutting rollers notch side rails to accept transverse rungs
WeldingRungs spot welded to notched side rails to complete ladder design
CuttingFinished cable tray cut to standard lengths
OutputFormed cable tray pieces exit the machine

The key components like forming stations, cutting dies, punching dies, welding electrodes etc. are customized to produce cable trays in different sizes and specifications. Advanced cable tray making machines have automated parts changing to switch manufacture different designs quick and easy.

Types of Cable Tray Making Machines

There are several types of cable tray manufacturing equipment that provide high productivity and flexibility –

1. Automatic Cable Tray Roll Forming Machine

FeatureDescription
OperationFully automatic PLC-controlled machine
Production RateUp to 15 meters per minute
Roller Stations16-18 progressive forming stations
ToolingQuick changeable forming rollers and dies
Designs ProducedAll standard cable tray types and sizes

These versatile CNC operated machines produce all types of cable trays like ladder type, solid/ventilated channel types, center spine designs etc. in one production line. Servo-electric puller feed system and rotary lateral shear provide high precision and efficiency.

2. Semi-Automatic Cable Tray Roll Former

FeatureDescription
OperationSemi-automatic with manual material feeding
Production Rate8-10 meters per minute
Roller Stations12-16 forming stations
ToolingMulti-profile tooling for size/design changes
Designs ProducedLadder type and channel type cable trays

Economical solutions perfect for small scale production requirements. Simple mechanical controls and manual material handling reduce the overall cost. Standard forming rollers can make changes in output cable tray sizes.

3. Motorized Cable Tray Production Line

FeatureDescription
OperationMotorized stations but no automation
Production Rate6-8 meters per minute
Roller Stations10-12 forming stands
ToolingFixed tooling for one tray type/size
Designs ProducedOne standardized cable tray design

Basic roll forming lines with manual controls suitable for producing cable trays in large volumes without variety. Dedicated tooling allows high throughput of one specific design like 150mm wide solid channel etc.

4. Customized Cable Tray Manufacturing Machine

FeatureDescription
OperationFully automatic customized features
Production RateUp to 20 meters per minute
Roller Stations20+ progressive bending stations
ToolingCustomized for special tray designs
Designs ProducedNon-standard and complex cable trays

For manufacturers looking for special designs and cross-sections, customized cable tray making machines deliver unique profiles. Addition of specialized processes like center spine forming, embossing, automatic welding and cutting stations make them extremely versatile for innovative cable tray shapes. Computerized control panel allows precision repeatability for consistent quality and output. These flexible solutions have high upfront tooling investment but facilitate mass production of proprietary cable tray assortments.

Raw Material for Cable Tray Making

Cable trays are predominantly made from steel and stainless steel metal sheets and coils. Galvanized steel, aluminum sheets may also be formed into trays based on corrosion resistance required.

Materialবৈশিষ্ট্যঅ্যাপ্লিকেশন
Mild SteelEconomical, strongIndoor electrical uses
Stainless SteelCorrosion resistantOutdoor/coastal areas
AluminumLightweightCable infrastructure
Pre-galvanized SteelRustproof coatingHumid and wet areas

The metal sheet coils need to undergo slit-edge/trimmed edge preparation for compatibility with the automated feeding mechanism of the cable tray manufacturing equipment. Coils are loaded on a de-coiler and fed into the machine for forming.

Applications of Cable Tray Systems

Cable tray systems find extensive use in industrial plants, buildings, infrastructure projects to route electrical cables and wires safely.

Application Areaবিস্তারিত
Power PlantsCable routing for control wiring, instrumentation, switchgear
Chemical IndustryHessian wrapped cables for corrosion resistance
Oil & GasDouble wall trays as flame barriers
Commercial BuildingsService channel raceways in false ceilings
Data CentersOverhead racks for network cabling
SubstationsSeismic certified trays

Cable trays provide neat accessible routing solutions for cable management critical for optimized performance and safety. Customized design and production via cable tray making machines cater to unique application needs.

How to Choose A Reliable Cable Tray Making Machine Supplier?

Choosing an established machinery manufacturer ensures a cable tray production line designed to maximize efficiency, safety and ROI.

ParameterWhat to Evaluate
Product PortfolioDiverse equipment range indicating advanced capabilities
Industry ExperienceLong track record of successful machine installations
Production FacilitiesCompany-owned infrastructure for quality assurance
Customization SkillsDesign talent and machining versatility
CertificationsISO accreditations for standardized process implementation
Service SupportResponsiveness for technical queries, maintenance etc.
ClienteleReputed companies already using their machinery

Prioritize suppliers who offer customized features in standard machines and even engineer special solutions from scratch based on unique specifications. Choose manufacturers open to imparting training to operate equipment as well as modify in-house later. Long-term partnerships facilitate scaling production optimally.

Installation and Working of Cable Tray Making Machine

Proper installation by technicians ensures smooth functioning of the cable tray manufacturing line.

Site Preparation

Taskবিস্তারিত
SpaceAllocate flat hard flooring of suitable load rating
শক্তিThree phase electrical connection
LightingAdequate illumination for safe working
AccessUnloading provision for machines/coils

Machine Assembly

Taskবিস্তারিত
PositioningFix machine stands firmly
LevellingUse spirit levels for uniformity
LinksConnect elementary sections
AlignmentPrecision adjust forming levels
Trial RunCheck functioning minus load

The supplier’s commissioning engineer will complete the installation process before handling over for production operations.

Working of the Cable Tray Making Machine

Operating the machine step-by-step:

StageWorking PatternControl Mode
LoadingPosition metal coil on de-coilerManual
FeedingAdjust feeder limit switchesSemi-auto
FormingMonitor dimensional accuracyAutomatic
PunchingActuate pneumatic piercingAutomatic
NotchingAdjust depth electronic stopsAutomatic
WeldingSet weld timer/temperatureManual inputs
CuttingUse shear limit switchesSemi-auto
CollectingManually unload finished piecesManual

The machine has manual, semi-automatic and fully automatic configured stations. Operators would initialize the process by setting parameters, loading raw material, troubleshoot errors by responding to the PLC alerts after which automated processes like forming, punching, notching, welding take over for high productivity with minimal manual intervention.

Maintenance of Cable Tray Manufacturing Equipment

Scheduled preventive maintenance enhances longevity and performance.

ActivityFrequencyMethodology
InspectionDailyCheck for leaks, wear, damage
CleaningWeeklyBlow dust, wipe visible parts
LubricationMonthlyApply grease through nipples
AdjustmentQuarterlyRealign forming stations, hydraulics
OverhaulYearlyReplace worn parts – belts, gears

In addition to regular upkeep, qualified technicians must troubleshoot and repair issues considering equipment safety standards. Document equipment parameters during maintenance for analyzing performance.

Cost Analysis for Cable Tray Manufacturing Business

Here is an overview of the economics involved in cable tray production using roll forming machinery:

Expense ItemsIndicative Cost
Automatic Cable Tray Machine$35000 to $55000
Manual Cable Tray Machine$15000 to $25000
Raw Material Coils$2.5 to $4 per kg
Skilled Machine Operators$500 per month x 3 shift operators
Maintenance Costs$2000 per year approx.
Factory Rental + Utilities$1500 per month approx.
Total Investment$100000 to $150000

Cable Tray Selling Prices

Cable Tray TypePrice per meter
Ladder Type Cable Tray$10 to $25
Ventilated Channel Cable Tray$15 to $30
Solid Bottom Cable Tray$12 to $20

Profit Estimation

Production DetailsIndicators
30 days per month x 1 shift of 8 hours240 production hours monthly
Output 10 meters tray/minute2400 meters output monthly
Selling Price $15 per meter$36000 sales revenue
Raw Material Cost 20%$7200
Gross Monthly Profit$28800

By maximizing production volumes across shifts, strategic tray sizes and optimal pricing – cable tray making business promises good returns on investment.

Cable Tray Making Machine
Cable Tray Making Machine 13

FAQs

Q: What thickness of sheets used for making cable trays?

Cable trays are commonly produced from 1-2.5mm thick HR steel sheets or stainless-steel coils. Thicker gauges provide higher load bearing strength. Choose appropriate thickness based on cable weights.

Q: What standards are cable trays manufactured to?

Cable trays conform to NEMA Ve-1 and IEC 61537 specifications covering mechanical performance, load ratings, bend radius, corrosion testing amongst other parameters. CE marking demonstrates conformity with EU directives for quality and safety.

Q: Can cable trays be bolted together for extension?

Yes, sections of cable trays can be joined together on-site using splice plates. Many manufacturers also offer hinged distribution boxes for connecting ladder type cable trays.

Q: How to determine the load capacity of cable trays?

Load capacity primarily depends on the cross-section, material thickness and supporting span length. Manufacturer test certificates detail permissible uniformly distributed load ratings that cable tray installations must follow.

Q: What accessories are used in cable tray installations?

Commonly used accessories include horizontal and vertical elbows, T and X connectors, reducers, covers, drops, risers, hinges, end caps, earth bonds, and fixation components like trapeze hangers, brackets, clamps and side rails.

Q: Can cable trays be grounded for safety?

Yes, earth continuity must be provided in cable tray systems using ): testing enables certification of integrity.

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