Step Beam Forming Machine

January 29, 2024

A step beam forming machine is an efficient automated metal fabrication equipment used to bend metal sheets and plates into various step beam structural shapes. This guide provides a comprehensive overview of step beam forming machine technology, working, components, capabilities, suppliers, applications, installation and more.

What is a Step Beam Forming Machine?

A step beam forming machine, also known as a step structural beam line, is a customized automated machine press brake that cold forms metal coils and sheets into step beams and structural channel profiles used in the construction, infrastructure, logistics and other industries.

The machine progressively forms the sheet metal fed through automated roller tables into unique step shapes with multiple built-in returns/lips along the web and flanges. The specialized CNC press brake tooling consisting of male and female dies, punch and dies, is customized to produce specific step beam configurations continuously.

Key Features of Step Beam Forming Machines

Automated roller tables for material feeding
Programmable servo-electric/hydraulic press brakes
Custom built-in tooling for forming steps
Touchscreen HMI, PLC and other automated controls
Modular designs for output flexibility
High degree of forming accuracy and repeatability
Low maintenance and operation costs
Output range from 50 kg to 1000 kg per hour based on model

Components of a Step Beam Production Line

A typical step beam forming system consists of several important sub-systems working together:

Table: Components of a Step Beam Forming Machine

Component	Description
Uncoiler and Feeder	Automated units that unroll and feed metal coil/sheet at adjustable feed rates
Guide Rollers	Straighten and guide sheets into the forming section
Press Brake	Presses down on sheet using specialized upper/lower tooling to form unique step configurations continuously
Controller	PLC/CNC control systems to automate and program entire forming process via HMI
Conveyors	Roller tables to automatically transport formed step beams for next processes
Decoiler	Winds and recoils finished product
Safety Enclosure	Full safety guards for operator protection

The various components are synchronized via servo mechanisms to coordinate material feed, speed, bending and discharge automatically for continuous production.

Modern step beam lines also include self-diagnostic systems, quick die change capabilities and various material handling accessories. Custom engineered solutions can produce different step profiles by changing tooling modules.

Working Process of a Step Beam Forming Machine

The working concept involves continuously cold forming metal sheets into unique step beam shapes utilizing an automated forming section.

Table: Step by Step Process Flow in a Step Beam Production Line

Stage	Working Description
1. Material Loading	Metal coils or sheets loaded onto powered de-coiler
2. Feeding	Automated feeder feeds sheet at preset feed rates into machine
3. Shearing	Optional end cropping shear to cut sheets to length
4 Straightening	Sheet passed through set of rollers to flatten/straighten it
5. Forming	Sheet pressed between upper and lower specialized dies to gradually form steps
6. Discharge	Formed step beam ejected onto exit roller tables
7. Recoiling	Optional re-coiling of finished beams into rolls by powered recoiler

The feeding, bending and discharge processes work continuously to produce high volumes of step beams per hour. Operators mainly load materials, monitor operations, inspect quality and replace tooling.

Modern computerized models allow easy programming of parameters like feed rates, stroke depth, punches per minute via the touchscreen HMI panel resulting in quick size/profile changes.

Key Specifications

Major parameters that define step beam line technical specifications:

Table: Technical Specifications of Step Beam Forming Machines

Parameter	Typical Range
Roller Table Length	5m – 12m or more
Material Thickness	2mm – 10mm
Material Type	Mild Steel, Stainless Steel
Sheet Width	1000mm – 2500mm
Bending Force	25 Ton to 100 Ton
Step Height	50mm – 300mm
Production Speed	10m to 30m per min
Production Capacity	50 kg to 1000 kg per hour
Power Supply	220V/380V AC , 15-50kW+

Custom step beam plants can be supplied to suit specific dimensional and output requirements.

Types of Step Beam Profiles Produced

Common standard and custom step beam profiles that can be formed by these machines include:

Table: Step Beam Shapes that can be Produced

Profile Shape	Description	Application
C Channel Steps	C sections with multiple lipped returns	Column beams, supports
U Channel Steps	U channels with formed lips	Heavy load bearing
Uneven Steps	Varying step depths in one web	Decorative and structural
Equal Steps	Uniform steps along full web	Modular structures
Z Section	Z shape with steps on flanges	Special architectural shapes
Tapered Steps	Progressively decreasing steps	Visual appeal

Advanced tooling designs allow forming channels, tapers, unequal flanges and almost any step beam shape on demand.

Raw Material for Step Beams

Commonly used materials for step beam profiles:

Mild steel sheets and coils
Galvanized iron coils
Stainless steel sheets
Aluminum sheets up to 4mm thickness

The uncoiler and feeding mechanism is equipped with dedicated roller tables for smooth loading and handling of steel, stainless steel and aluminum coils without damage.

Structural Step Beam Applications

Step beams provide excellent load bearing capacity similar to standard I beams but with decorative shapes. Common applications include:

Industry

Warehouses
Factory structures
Steel plants
Commercial buildings

Infrastructure

Metro stations
Bridges
Railways
- Platform roofs

Transportation

Container chassis
Tipper trailers
Truck chassis

Agricultural

Greenhouses
Farm equipment

Logistics

Racking systems
Mezzanine floors
Shelving

Marine

Ships
Offshore platforms

Defense

Military vehicles
Remote installations

The automated process allows mass production of step beams in standard and custom sizes as per application requirements.

Step Beam Tooling Modules

The male and female tooling dies utilize complex tool piece modules that collectively form each step. Common tooling elements include:

Table: Tooling Modules in a Step Beam Machine Press Brake

Module Type	Description
Guiders	Guide sheet into forming zone
Locators	Align sheet precisely
Grippers	Firmly grip sheet
Formers	Female dies to create basic step shape
Punches	Male dies to press sheet into female dies
Goosenecks	Form lipped returns
Directors	Guide formed profile out

These special tool pieces combine to produce continuous stepped channels via synchronized sequential movements. The open architecture allows replacing only certain modules like punches and dies to alter step configurations.

Buying Factors – Choose Right Step Beam Making Machine

Key considerations for selecting a step beam production line:

Table: Checklist to Select Best Step Beam Making Machine

Parameter	Description
Production Output	Match speed, thickness and width to output rates needed
Profile Variants	Tool flexibility for standard and custom shapes
Material Type	Compatibility for steel, aluminum, stainless steel
Length Range	Roller tables, shear to suit beam lengths
Control Type	Ease of programming via PLC/CNC
Die Type	Quick change modular tooling preferred
Safety	Must have full operator protection guards
Automation Level	Auto material feed, discharge and other functions
Post-sales Service	Installation support, maintenance and warranty
Machine Finish	Robust all-welded frame structure
Budget	Compare model price versus production capacity

Reputed manufacturers provide customizable step beam forming equipment built to specifications.

List of Step Beam Machine Manufacturers and Models

Table: Leading Step Beam Making Machine Brands and Models

Brand	Model Range	Location
Anhui Yuding	YD WM/WMS	China
Jurmex	JBC/JBM	Taiwan
Sahinler	Beam Line	Turkey
IMC	Megaform	India
Techno Designs	TDS	India
Durma	AD-R/RX	Turkey

Pricing Estimate

Typical price range for new step beam production lines based on capabilities:

Table: Price Range Estimate for Step Beam Making Machines

Capacity	Price Range
50-100 kg/hour	$30,000 to $60,000
100-250 kg/hour	$60,000 to $150,000
250-500 kg/hour	$150,000 to $300,000
500-1000 kg/hour	$300,000 to $500,000

Higher output custom engineered solutions with more features, automation and accessories will be priced higher. Getting quotations from shortlisted suppliers is advised.

Installation and Operation

Step beam plants require about 200-250 sqft of covered shop floor space for setup.
Dedicated material loading and forming sections needed with minimum 5-6m length.
Power requirement is generally 25kW to 50kW based on press brake motor capacity.
Machines are shipped pre-assembled in containers for quick installation using cranes, forklifts before commissioning.
Supplier technicians commission the line and provide training on working procedures.
1-2 semi-skilled technicians can operate the line by monitoring process parameters on HMI panel and via control switches.

Routine maintenance involves cleaning of tooling, oil levels check and observing performance. Production planning is entering coil dimensions and required beam sizes.