Corrugated Roof Sheet Roll Forming Machine

Roofing system roll forming machine is used in an extensive range of metal sheet profiles. It includes trapezoidal panel, corrugated panel, roof tile panel, step tile, glazed tiles, metal deck panel, standing seam panel, K span panel and ridge cap. Its products are widely used in roof and wall system in workshop construction and housing construction.

The normal thickness range of roof panel roll forming machine is 0.2mm-0.8mm, the standard or more used in international market is Gauge 26 (0.45-0.5mm), working raw material is Aluminum, PPGI, Galvanized steel, etc. We confirm machine’s configuration according to your drawing, specially the pitch and height of each wave.

The standard machine speed can reach about 20M/min, if the capacity is big, we can make the machine speed which can reach 25-30M/min. And some customer they require the thickness of the roofing sheet is 1.2mm, it is ok too. If you want learn more of this kind of machine, choosing our company is your best option.

Here is one drawing profile and finished product:

Corrugated Roof Sheet Roll Forming Machine

Production technology process:
Feeding → Leveling → Forming  → hydraulic Cutting after forming  → Output

The price of ZTRFM’s roll forming machines is a little higher than other suppliers’. Let me explain about our machines difference:

ZTRFM’s machine design: it is unit one, which means the control box and the hydraulic station are all put under the machine frame, when you get the machine, no need to assemble and connect the complicate cable of the machine, you only need to connect one main cable, then the machine is working. it saves more time and space.

Our display screen is touch screen, not text touch screen.

ZTRFM Processing technology:ZTRFM rollers is through grinding, quenched, chroming,finish machining,polishing,coated with chrome 0.05mm, all rollers are shiny, stronger and avoid rust.etc to make stronger, the roll forming machine is more robust and easier to use.  The metal sheet produced by our machine is always flat and perfect profiles., because in the design and during the machining process, we always control the force for the metal sheet, it does not damage the sheet surface and comes out perfect profile.

ZTRFM roll forming system: We will make the hand wheels at the feeding device to adjust feeding width, and we also make the wheels with the numbers then you know how to adjust right and left sides, also we made the rulers on the bedding, you can adjust the profile height and width according to the rulers.

Screw with numbers is to adjust material thickness easily, also with protecting cap also add laminating film device and felt to make the board flatter and smoother without scratches.

The  machine is equipped with a detection switch device, in case of emergency, emergency alarm, stop operation.

 

Profile drawing (Material thickness 0.6 mm)

50*50*50*12mm,Material thickness:to 0.6mm,Hole diameter:60mm

C light keel roll forming machine of Section Description

3 T Manual decoiler

1.This part can manually tighten or shrink the core, so that the loading and unloading of the roll is very convenient.

2.This device can tighten the stainless steel coil. Because the stainless steel coil is very narrow, the coil with a long outer diameter is easy to become loose during use. A longer tightening device can be customized for you to prevent the stainless steel coil from becoming loose , To prevent the interruption of the operation of the door frame equipment, causing danger!

3.The decoiler is equipped with a manual brake. Once a danger occurs during the operation of the equipment into the roll, the operation of the decoiler can be stopped immediately to prevent the occurrence of danger.

Roll forming system of light keel roll forming machine

1. The machine is equipped with lifting holes and has been reinforced. The loading and unloading of the machine is very easy, and the machine itself will not be damaged by loading and unloading the machine. As we all know, the machine is prone to loosening a part of the screw or violent packing during the loading and unloading process. The inevitable consequences of machine cracking, painting, bending, etc., will cause serious problems such as deviation and small sides after the machine is running.
2. The feed guide roller is made of Cr12 material and is chrome-plated to increase the hardness of the feed guide roller. Some manufacturers use other materials or paint, and there is no difference in appearance, but after a few months of use, the paint will be worn and dropped. , The original material is exposed, and it will rust or be damaged if used for a long time.
3. Several rows of such side rollers, also called vertical rollers, are added inside the forming machine. The function of this side roller is to prevent the sheet from deviating, and to make the small side of the sheet perfect, reduce the impact of small side springback, and consolidate Molding effect.
4. The machine uses 8.8 grade bolts, which have high tensile strength and yield strength, and have been boiled black, which has strong corrosion resistance. The service life can reach 10 to 15 years. The cost of a bolt is 2 to 3 for ordinary bolts. Double the price. If you use ordinary bolts and use them for a long time, the bolts are prone to loose or rust when the machine is running, which will cause inaccurate forming of the sheet or the machine will not run, damage and stop, which will hinder your business.

5.  The nuts for fixing the gantry wall panels are also boiled black and have high corrosion resistance. As we all know, when we adjust the machine or change the mold, we need to remove the nuts frequently. Once they are corroded and rusted, we need to replace the nuts. The cost is also very high, many manufacturers do not carry out this part of the process, our nuts are 2 to 3 times the price of ordinary nuts.

6.   The drum is made of Cr12 material, quenched and chrome plated. For galvanized materials, there are very high requirements on the rollers. Some manufacturers did not implement the correct process. In order to save costs, the chrome plating time is short or quenching is not performed, and sometimes only part of the roller is processed. As a result, the roller has a short service life and is easily damaged.

7.   The machine wall panel adopts a cast iron arch structure with a thickness of 28mm. This structure makes the machine run more stable.

8.Adopt Omron counter, this kind of counter has long service life and accurate automatic counting.

PLC control system

9.Manual touch screen, and all large screens are used. We use the Delta brand, which is easy to operate, fast and accurate, and can design a variety of parameters and functions.

10.For buttons, we usually use Schneider brand. Common electrical components have a short service life. Once broken, it is difficult to find matching repairs. However, Schneider is a global warranty and the after-sales service is very convenient.

11.Generally, the electric cabinet box in the factory is painted. After a long time, the paint is easy to fall off. The electric cabinet box we use is painted. For a humid environment, it has a long service life and will not lose the paint. Our electric cabinet box shell is more Thicker, reflected in the weight, and stronger.

12. The electric cabinet is equipped with an intelligent heat dissipation system, which can run for a long time and has a long service life. The electrical materials are also internationally renowned brands. The original electrical appliances can be purchased as accessories abroad, which are very durable and convenient.
13. Using this kind of aviation plug for wiring makes it easy to connect the electricity to the main engine, petrol station, and motor, so we won’t have installation and after-sales problems, and this wiring method is very safe.

Hydraulic oil pump station

14.  The hydraulic oil station is equipped with an air-cooled device, and the machine can run for multiple hours without stopping, which will continue to last for your business and have a long service life.

15.  The solenoid valve adopts the Japanese Yuken brand, which is durable and not easy to damage.

16.  The oil pump adopts new technology and produces very little noise.

17.  The tank is thickened and uses a large fuel tank to provide strong power for the operation of the machine, which is 2 to 3 times the price of an ordinary fuel tank. The ordinary fuel tank is prone to oil leakage and cannot be started. This is very durable.

cutting system

18.The cutting blade is made of Cr12 material and quenched. It has strong wear resistance, stability, compressive strength and other characteristics. Will not bend or crack after long time use. Galvanized material has better cutting effect and is very durable.

product collect table

19.This kind of material receiving rack can be manually packaged while receiving materials, which is convenient to operate and practical and stable.

Automatic one button switch C to Z CZ purline rolling forming machine

Automatic one button switch C to Z , CZ purline rolling forming machine is the most smart type C and Z purline rolling forming machine. It can control the shape changing from to C to Z by one button switch, it can reduce the requirements for professional and technical workers,save more time and Labor cost then can improve work efficiency and reduce the waste of materials. Here we will take the following drawing profile for your reference:

 

 

About the sizes of range: for the C purline, we divide it into three ranges, From C100 to C150,

From C 150 to C240mm,  from C240 to C300 like this. In the different ranges, the thickness supported range is also different. The same working principle to the Z purling profiles.

 

Automatic CZ purline rolling forming machine:

Supported Material:

1.5mm Minimum Thickness, 3.25mm Maximum Thickness 2.0mm for inspection

CR, HR, HRPO STEEL, Galvanized Plain CR Steel     Yield strength: 450Mpa

 

Automatic CZ purline rolling forming machine working layout:

 

More detail elements introduction, actual lots of elements are optional.

5Ton*650mm Hydraulic Un-coiler

Hydraulic system to expand coil inner hole；Pump motor：3KW；

Frequency Inverter to regulate turn speed；Motor：3KW

Coil Inner-diameter= 470-560mm. Coil Outer-diameter Max. 1600mm；

Link-connect expanding system

Load Capacity: Max. 5 Tons; Coil Width Max. 650mm；

Hydraulic Holder on the top to hold the sheet, keep press all the working time, special design on the hydraulic group

 

Pre-Leveling Device: In order to make the coil neat and clean, we design the special leveling system.

Meanwhile it also designed with the servo motor, when then coil width changing, it will do the size changing automatically.

 

Pre-shearing is optional: (You can choose to add or not.)

Sheet feeding guide section with width variation.  Powered feed in rolls. Stop to Punch, stop to cut.

Hydraulic Pre-shearing device, manual control, only for cutting the first piece and the end piece of the sheet

Pre-cutting device, PLC control, purlin has bit open-up in both ends; panel, length min 2.5m

 

Hydraulic group, Pump motor =18.5KW (Before punching and after punching )

Total Three sets of punching stations

Station 1 : Web Punch – One round hole of dia 14mm

Station 2 : Web Punch  – One pair of oval hole on web, size 14*22 mm

Station 3 : Flange Punch – One pair of oval hole on flange, size 14*22 mm

Extra set of die for punches of size 18*25 mm

They are exchangeable

Hydraulic group, Pump motor =18.5KW

For some holes, we do the punching before rolling forming, for some holes we do the punching after rolling forming. Here are some pictures for your reference:

Automatic CZ purline rolling forming machine

The feeding section with guide;

Gear/Sprocket driving, 18-step to form

Frame stand Construction，H beam base，with leveling bolts in the base to adjust the level

Rollers manufactured from Cr12（D3）, Heat Treatment.

Shaft Diameter=Φ75mm, Precision Machined, heat Treatment

Sizes Changing: Movable design of one side/Dovetail slot structure.

By PLC control-setting size in PLC to reach the size requested (incl.width, flange, lip)

Changing from C to Z or Z to C automatically by PLC

Adjust the size of C, Z automatically according to setting parameters by PLC.

-setting size in PLC to reach the size requested (incl.width, flange, lip)

Main Motor=22 KW

Forming speed approx. 0-25m/min

Note: even if we design the sides and shape changing by PLC, we also allow you to do the changing by button control and handrail. In case some of mistake and then you can adjust a little bit.

 

Hydraulic post Innovative Cutting

Stop to Cut, Post Cut, Innovative cutting system, C/Z integrated & adjustable cutting mold

Cutting tool material: Cr12

Even if we call it as automatic but the size changing of cutter, we need to adjust by the worker. When the profile bigger or smaller, simple adjust it by the handrail up and down.

 

 

Automatic stacker part:

Equipment overview

C80-300 and Z100-300 full-automatic stackers can stack C/Z purlins with the same set of equipment. The whole set of equipment consists of servo motor, PLC and PRC touch screen, forming a complete control system. It has the advantages of simple structure, beautiful interface, reliable performance, convenient operation and high production efficiency.

Incremental encoder is used to fix the length. It can be controlled manually and automatically. The main low-voltage electrical components adopt international famous brands such as Schneider.

 

Automatic one bottom control C to Z CZ purline rolling forming machine working videos for your reference:

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If you need more information, please contact us at any time.

 

Combined stud and track rolling forming machine is designed based on the idea of one machine for two or more types profiles like stud and track meanwhile two profiles could work together. Those two profiles can work at the same time. Here I will take the following drawing profiles for examples.

 

Combined stud and track rolling forming machine:

Main Machine of Combined stud and track rolling forming machine:

Size: 4800х1800х1400Weight t: 3.2tons

Voltage:380V/50HZ3Phase(as customer’s request)

Roller fixer : Guide column

Frame : middle plate welded

Memorial arch frame type

Frame thickness:25mm

Drive mode: gear

Material of rollers: GCr12MoV

Material of shafts: 40Cr steel with tempering

Diameter of shafts: φ60mm

Number of rollers for wall angle stud :11 rollers

Number of rollers for C channel :14 rollers

Main power: 5.5 kw for each part

Cycloidal planetary gear speed reducer

 

Punching holes The hydraulic station to punch holes, one station.

The molds are changeable. We will give related holes molds.

Servo tracking shearing system Material of blades: Gcr12 quenched

Power supply : hydraulic power

Frame : Pillar style with rack & pinion system

Stroke switch :  non-contact photoelectric switch

We will give more cutting blades for you to change to fix those different drawing profiles.

Hydraulic Station

Hydraulic motor Power: 5.5kw for each one

Hydraulic oil: 46#

Components: The system includes a set of hydraulic tank, a set of hydraulic oil pump, and two hydraulic pipes. And three sets: one is for punching hole; one is for printing words and one for cutting.  Sets of electromagnetism valves.

Electric Control System Feature:

1. Adopted PLC, transducer, touch panel from Delta Taiwan to ensure high speed with stability, precision and lifetime.

2.Other electric element are Delta

3. Equipped with movable switch, air break, radiator, transformer & electric leakage protector for operation convenience and safety.

The advantages of Combined stud and track rolling forming machine:

1. Two lines together, it takes up small space.
2. One worker can watch the production of two lines.
3. Two types speed machine design optional, normal speed like 25m/min and high speed design like 45 meter per minute.
4. As to the cost, it is more or less same like two lines.
5. It is good for those whose factory is quite small but needs to hold more machines.

 

We have another options for your reference: If you budget is so limited you can choose to use one shaft with two types rollers like the following machines. But we need to discuss to check whether two profiles could be made like this or not.

Combined stud and track rolling forming machine working videos for your reference:

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Introduction of New Aluminum Solar PV Panel Frames

L-shaped closed steel frame (photovoltaic panel frame), using the design and simulation module of Copra software, showing the powerful design and accurate simulation analysis functions, improving the design efficiency, and reducing the error costs.

Parameter of New Aluminum Solar PV Panel Frames

Copra software provides a variety of board width calculation methods (such as standard formula and DIN6935, both methods are used in this case). According to the final product section, the initial feed board width is 155.49mm.

 

The surface of the feed strip is galvanized magnesium-aluminum coating, the yield strength is 365MPa, the tensile strength is 490MPa, the elongation is 16%, the Poisson’s ratio is 0.3, and the Young’s modulus is 210GPa.

The knurled design of New Aluminum Solar PV Panel Frames

The number of roll forming passes of this section is 41.

The software provides a variety of unfolding forming methods for corner unfolding. This section adopts two methods: constant length of neutral layer and fixed radius.

The software provides a convenient roll design-spreadsheet function, which can help engineers to quickly develop and modify the section.

The Roller flower rationality verification  of New Aluminum Solar PV Panel Frames

The software provides a rapid verification tool for the rationality of the roll pattern design. The state of the strip after each pass is shown in the figure, and the longitudinal strain of the edge of the strip is displayed in different colors when it passes through each pass.

 

 

The longitudinal strain value of each pass is displayed in the form of a bar chart, which is used to verify whether the forming angle and forming number of each corner are reasonable. As shown in the figure, the forming longitudinal strain of each pass meets the design requirements.

Roll Design of New Aluminum Solar PV Panel Frames

The software provides a variety of roll design and correction functions, which can quickly obtain the matching roll drawings, and can quickly export the drawings and roll weights. As shown in the figure, the blank width and diameter can be quickly obtained. The blank weight is about 414.63Kg.

 

The software can quickly convert the designed two-dimensional graphics into three-dimensional entities, and quickly check whether the arrangement of the rolls is reasonable and the forming characteristics of the sheet, as shown in the figure below.

Simulation of New Aluminum Solar PV Panel Frames

Through Copra software, design drawing files can be quickly converted into finite element models, and calculations can be submitted quickly, reducing the operation process from design to simulation.

Simulation Results of New Aluminum Solar PV Panel Frames

The software provides a cross-section comparison function, that is, the cross-section of the simulated strip passing through each pass is compared with the cross-section of each pass designed by the user. The picture shows the cross-section comparison of the 5th pass. The red curve is the cross-section of the simulated strip, the blue is the cross-section designed by the user, and the green is the cross-section of the simulated strip after rolling out of the roll.

Users can check the transverse flow of the strip, the springback of the strip after it rolls out of the roll, and the shape of the strip at each moment, and can measure the extension distance and springback angle of the strip. Through the cross-sectional comparison, it can be seen that the R angle at A rolls back out of the roll.

When the profile is rolled out of the last pass, the cross section of the simulated strip (red) is extracted and compared with the design section of the last pass (blue). By comparison, it can be seen that the profiles in area A are well formed and meet the design requirements; the profiles in area B are slightly deviated from the design due to the springback and the forming force of other parts; the profiles in area C are not ideally formed, because the profiles are in The lateral flow of material occurs during the molding process, so the size of the profile at this position has deviated from the design size before the C area is formed, and further optimization of the design is required.

When the profile is rolled out for the last pass, the front end of the feed is cut off, leaving the profile as shown in the figure, showing the Y-direction cloud map (thickness direction). It can be seen that the middle position of the profile (indicated by the arrow) is bulging. Since the diameter of the lower roll in all passes is fixed, the profile may be longitudinally squeezed when entering the roll. In the later optimization, the method of increasing the diameter of the lower roller can be used to keep the profile in a stretched state.

When the profile is rolled out for the last pass, the front end of the feed is cut off, and the thickness variation curve of the profile is extracted. As shown in the figure, the thickness of the corner area is reduced, and the specific size can be viewed in the longitudinal coordinate value.

Through the Copra software, the force of the rollers in each pass can be viewed (all passes, up and down, left and right and inclined roller axes, different directions). As shown in the figure, it is the force in the Y direction (thickness direction) of the roller under all passes, which is also the maximum force direction of the roller. It can be seen that when the profile passes through 31 passes, the lower roller is the most stressed, and the force value is about 0.58 tons. The user can judge whether the roll shaft diameter meets the design requirements.

The wear of the profile after passing through the rolls can be viewed through the Copra software.