11.12.2025 / 4-minute read

15-Ton Sheet Flipping Machine for Automotive Stamping Lines | Heavy-Duty Material Handling

Project Overview

Client: Automotive Manufacturing Plant

Industry: Automotive Manufacturing

Application: Stamping Production Line

Core Challenge: To automate the flipping process of large sheet stacks (up to 15 tons) between stamping operations, eliminating manual handling while ensuring surface quality and operational safety.

Basic Parameters

Parameter Category	Technical Specification	Notes/Details
Load Capacity	15 tons	Including racks
Material Size Range	Length: 800-6000 mm Width: 400-3000 mm Thickness: 50-800 mm	Excluding rack thickness Sheet stack height ≤600mm
Structure Type	“O”-frame structure	Opening ≥1200mm
Work Cycle	Flipping speed: 100s/180° Complete cycle time: ≤200s	Variable frequency speed regulation
Clamping System	4 hydraulic cylinders Clamping speed: 50 mm/s Release speed: 60 mm/s	Pressure adjustable
Drive System	Motor + Reducer	Variable frequency speed regulation
Conveyor System	Roller conveyor speed: 0-8 m/min	Variable frequency adjustable
Power Requirements	AC380V, 50Hz	Standard industrial power
Installation Requirements	Shallow or no foundation	Reduces installation costs
Safety Features	Multiple limit protections Motor with brake Buffer devices	Ensures operational safety

The Challenges

Manual Handling Risks: Traditional crane/flip methods posed safety hazards and potential sheet damage
Inconsistent Cycle Times: Variable flipping speeds created production bottlenecks
Surface Quality Concerns: Previous methods caused scratches and surface defects
Labor Intensive: Required multiple operators for heavy sheet stack manipulation

Solution

Scratch-Free Material Handling: Equipped with polyurethane buffer pads and finely-machined rack surfaces to completely prevent scratches and surface damage to expensive metal sheets during the flipping process.
Adaptive Clamping System: The hydraulic clamping system automatically adjusts pressure based on stack height and weight, featuring overload protection to prevent material deformation or crushing.
Precision Speed Control: Incorporates variable frequency drive for smooth acceleration and deceleration, with customizable fast-slow speed profiles to ensure flipping stability and minimize material shift.
Multi-Layer Safety Protection: Combines programmable limit switches, mechanical hard stops, and motor brakes with self-locking capability to prevent over-rotation and ensure secure stopping at any position.
Shock Absorption Technology: Integrated buffer devices at both start and end points absorb kinetic energy during flipping, delivering smooth operation with minimal impact and noise levels below industry standards.
Flexible Material Compatibility: Customizable fixture designs accommodate various material types including steel, aluminum, and copper plates, with width adjustment mechanisms for different stack dimensions.
Low-Maintenance Design: Features a welded steel plate cylindrical structure with shot-blasted surface treatment for enhanced durability and corrosion resistance in industrial environments.
Energy-Efficient Operation: Optimized power consumption through intelligent motor control and automatic system standby during non-operational periods, supporting sustainable manufacturing goals.
Shallow Foundation Requirement: Engineered for installation with minimal or no foundation work, significantly reducing installation time and civil engineering costs.
Automation-Ready Interface: Equipped with detection switches at both flip start and end positions for seamless integration with automated production lines and MES connectivity.