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Cable Tray Roll Forming Machine Series
Overlap-Type Cable Tray Roll Forming Machine
Overlap-Type Cable Tray Roll Forming Machine
Overlap-Type Cable Tray Roll Forming Machine
Overlap-Type Cable Tray Roll Forming Machine
Overlap-Type Cable Tray Roll Forming Machine
Overlap-Type Cable Tray Roll Forming Machine
Overlap-Type Cable Tray Roll Forming Machine

Overlap-Type Cable Tray Roll Forming Machine

The Overlap-Type Cable Tray Roll Forming Machine is specialized equipment designed to manufacture cable trays featuring swaged or flared connection ends. Through a specialized roll design, the machine forms precise connection interfaces at the tray ends, enabling rapid on-site assembly and installation. Suitable for the production of engineering-grade cable trays, the equipment effectively enhances construction efficiency and reduces installation costs.

Overlap-Type Cable Tray Roll Forming Machine (Flared/Swaged Plug-in Type) — Features single-end flaring or swaging for direct end-to-end insertion, saving both labor and material.

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Equipment Introduction

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I. Equipment Introduction

The Overlap-Type Cable Tray Roll Forming Machine is an automated cold-roll forming system designed specifically for producing plug-in, overlapping cable trays. Utilizing a continuous roll-forming process, the machine integrates uncoiling, leveling, punching, end-forming (expanding or reducing), and cutting into a single, streamlined operation to produce finished cable trays directly.

These cable trays feature a unique end-forming design: one end is processed to be either expanded or reduced, while the other remains a flat end (retaining the original raw material cross-section). During installation, the flat end of one tray section is inserted directly into the expanded or reduced end of another; a secure connection is achieved through the overlapping fit and friction between the ends, eliminating the need for connecting plates or bolted fasteners.

The dimensions for the expansion or reduction are set at 0.6 to 0.8 times the thickness of the sheet metal. The expanded/reduced ends and flat ends are formed through a single-pass process, ensuring high product consistency and precision. As the flat end retains its original cross-section—unaffected by the expansion or reduction process—smooth insertion and a tight fit are guaranteed.

II. Key Advantages

1. No connecting plates; significantly reduced costs
Traditional connections require various accessories such as internal and external connecting plates and bolts.
The single-end flared/swaged slip-fit ​​connection eliminates the need for connecting plates, relying solely on end-deformation to achieve the overlap.
The variety and quantity of accessories are drastically reduced, lowering procurement costs and inventory pressure.

2. Direct end-to-end insertion; doubled installation efficiency
The flat end inserts directly into the flared/swaged end, eliminating the need for precise end-face alignment or positioning of connecting plates.
Installation is simplified to a single insertion step, saving significant construction time.
Particularly suitable for large-scale, long-distance cable tray installation projects.

3. Stable connection; high overall structural strength
The flared/swaged end provides an enveloping fit around the flat end, ensuring a large contact area and a tight connection.
No bolts are required for locking; the connection is secured by the enveloping force between the ends.
The connection point is smooth and robust, ensuring structural integrity and facilitating easy future maintenance.

4. Simple structure; safe and reliable
Simple structure allows for quick installation and easy securing.
No additional accessories or components are required for connection or fastening.
Eliminates safety hazards associated with delays in replacing damaged components.

5. European standard compatibility; hassle-free exports
Complies with international standards IEC 61537 / EN IEC 61537.
Compatible with various materials, including pre-galvanized steel, cold-rolled steel, and stainless steel.
Surface treatment options include pre-galvanized, hot-dip galvanized, electrostatic powder coating, and aluminum-magnesium-zinc coating.


III. Comparison with Traditional Lap Joint Methods
Comparison Item: Single-end Flared/Swaged Insert Connection vs. Traditional Connecting Plate Lap Joint
Connection Accessories: No connecting plates required; requires internal/external connecting plates and bolts
Installation Steps: Single-step insertion; align ends + position connecting plates + tighten bolts
Installation Efficiency: Very high; Moderate
Connection Stability: Enveloping connection; stable and reliable. Relies on bolt tightening
Accessory Cost: None; High


IV. Application Areas

Thanks to advantages such as cost-effectiveness, rapid installation, and simple structure, single-end swaged (flared/reduced) plug-in cable trays are widely used in:

Large-scale engineering projects: Long-distance cable laying where installation efficiency is critical

Projects for export to Europe and international markets: Compliance with IEC 61537 standards and full documentation support

Power systems: Cable support and routing in power plants and substations

Industrial facilities: Power and control cable management in factories and mines

Rail transit: Cable support for high-speed rail, metro stations, and tunnels

Data centers and telecommunications: Cable management in server rooms and communication base stations


V. Production Process

The end-expanding or end-reducing process is completed in a single pass on the roll forming line:

Uncoiling → Leveling/Flattening → Servo Feeding/Punching → Guided Infeed → Roll Forming → Cut-to-Length (including single-end expansion or reduction) → Finished Product Discharge

Process Step Description
Uncoiling: Hydraulic uncoiling to support and feed the steel coil
Leveling/Flattening: Multi-roller leveling to eliminate internal stress and ensure forming precision
Servo Feeding + Punching: Precise positioning and punching of various hole patterns
Guided Infeed: Automatic material guiding and alignment; accommodates varying widths
Roll Forming: Automatic profile changeover for different specifications
Cut-to-Length Automatic length measurement; hydraulic cutting & end expansion/reduction
Finished Product Discharge: Output of finished products; smooth line operation


VI. Service & Support

Solution Design: Personalized equipment selection and production line layout based on customer drawings and capacity requirements.

Custom Manufacturing: Support for non-standard customization; full control over the process from roll design to complete line manufacturing.

Installation & Commissioning: On-site installation and commissioning by engineers, including on-site operator training.

After-Sales Support: Long-term technical consultation and spare parts supply; engineers hold valid visas and are available for on-site service worldwide at any time.

Standards Support: Provision of technical documentation confirming compliance with the IEC61537 standard to assist customers with export certification.


VII. Why Choose Us

Nearly 20 years of manufacturing experience: Mature technology, refined processes, and reliable quality

Direct manufacturer: No middlemen, offering excellent value for money

European standard manufacturing capabilities: Production strictly adheres to IEC 61537 / EN IEC 61537 standards

Proven single-end expanding/swaging process: Single-step forming ensures high precision and consistency

Global service network: Engineers hold all necessary visas, ensuring rapid response

Item Parameter
Shaft diameter Φ80 mm (CNC turning followed by super-precision grinding)
Spindle material High-quality 40Cr, quenched and tempered (HB 220–260)
Forming machine motor power 2 x 15 kW; K-series gear reducer
Traversing motor 2 x 0.75 kW + 1 x 2.2 kW
Forming line speed 2–10 m/min; cut length > 3 m
Number of forming stations Cable tray: 24 stations; cable tray cover: 12 stations (overhead hoist system)
Roller material Cr12MoV (CNC machined, hard chrome-plated surface)
Roller sets 2 sets (quick-change forming modules for different thickness ranges)
Roller heat treatment Quenching (HRC 58–62)
Safety guard Protective housing installed on the drive side

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Uncoiler-Leveler Integrated Machine — Servo Feeding & Punching — Accumulation Pit — Guided Infeed — Roll Forming — Hydraulic Cutting — Outfeed

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About
Wuxi Yanwu Xinhui Technology Co., Ltd.

Established in 2012, Wuxi Yanwu Machinery Co., Ltd., is a professional manufacturer specializing in the R&D, design, manufacturing, and servicing of cold roll forming equipment. The company is dedicated to providing global customers with integrated solutions for automated cold roll forming production lines.

Our main products include cable tray forming machines, racking forming machines, C/Z purlin machines, solar mounting bracket forming machines, floor deck machines, door frame machines, automotive profile equipment, and cut-to-length/slitting lines.

These products are widely used in the construction, electrical power, logistics and warehousing, automotive manufacturing, new energy, and infrastructure sectors.

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News
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