Cold Roll Forming Machine

A Cold Roll Forming Machine is a specialized piece of equipment used to shape metal sheets or strips into various profiles at room temperature.Here is a detailed introduction:

Working Principle

The machine operates based on the principle of sequential plastic deformation of metal materials.A coiled metal strip is first unwound by the uncoiler.The uncoiled strip then passes through a leveler to eliminate any irregularities such as waviness or camber caused during the rolling and transportation processes.

Subsequently,the flattened strip enters the roll-forming unit,which consists of a series of roll stands.Each roll stand has a pair of rolls with specifically designed profiles.As the strip moves through these roll stands,it is gradually bent and shaped into the desired cross-sectional profile.For example,to produce a C-shaped steel profile,the strip is successively bent and formed into a C-shaped contour by the rolls.

After the profile is formed,a cutting device,such as a flying saw or a shearing machine,cuts the continuously formed profile into the required lengths according to the pre-set dimensions.

Main Components

Uncoiler

The uncoiler is designed to hold and unwind the metal coil.It is equipped with a tension control system to ensure a consistent and stable tension during the unwinding process.This helps prevent the strip from wrinkling or stretching unevenly.The main components of the uncoiler include a mandrel,which can expand and contract to hold the coil firmly,a base for support,and a drive system to rotate the mandrel.

Leveler

The leveler plays a crucial role in flattening the uncoiled metal strip.It typically consists of multiple pairs of leveling rolls arranged in an alternating up-and-down pattern.By applying a reverse bending force to the strip,the leveling rolls cause the strip to undergo elastic-plastic deformation,thereby eliminating its initial unevenness.The number,diameter,and spacing of the leveling rolls can be adjusted according to the thickness and material of the strip being processed.Some advanced levelers are equipped with an automatic adjustment function that can adapt to the flatness of the strip in real-time.

Roll-Forming Unit

This is the core part of the cold roll forming machine.It is composed of multiple roll stands.Each roll stand contributes to the progressive shaping of the strip.The rolls in these stands are custom-designed according to the target cross-sectional profile of the product.They are usually made of high-quality alloy steel and undergo heat treatment to enhance their hardness and wear resistance.

The roll-forming unit also includes a robust frame to support the rolls,a transmission system to ensure synchronous rotation of all rolls,and a roll-adjustment device.The roll-adjustment device allows for fine-tuning of the roll positions,enabling the production of different-sized profiles.

Cutting Device

There are two common types of cutting devices:the flying saw and the shearing machine.The flying saw uses a high-speed rotating saw blade to cut the moving profile.It is suitable for cutting large-sized and high-strength profiles,offering fast cutting speed and good cut-edge quality.The shearing machine,on the other hand,uses a punching and shearing mechanism to cut the profile by applying an impact force.It is simple in structure and cost-effective,often used for cutting medium-and small-sized profiles.

Control System

The control system is responsible for the automated operation of the entire cold roll forming machine.It usually has a Programmable Logic Controller(PLC)or an industrial computer as its core,coupled with an operator interface,such as a touch-screen.

Operators can set various production parameters on the interface,including uncoiling speed,leveling parameters,roll-forming speed,and cutting length.The control system continuously monitors the operating status of the machine,such as the rotation speed of motors,roll pressure,and profile length.In case of malfunctions,it can promptly issue an alarm and display fault information,facilitating quick troubleshooting by maintenance personnel.

Technical Parameters

Processable Sheet Thickness

This is an important indicator of the machine's processing capacity.Commonly,the range is from 0.5mm to 10mm,although different models may vary.Processing thicker sheets requires greater rolling force,placing higher demands on the structural strength of the machine and the material of the rolls.

Processable Sheet Width

Generally,it ranges from 100mm to 2000mm.The width of the sheet that can be processed determines the maximum width of the profiles that can be produced.Processing wide-width sheets requires higher stability and precision control of the machine.

Production Speed

The production speed typically ranges from 5 to 60 meters per minute.The speed is influenced by factors such as the type of machine,the size and complexity of the profile.Simple profiles can be produced at a relatively high speed,while complex cross-sectional profiles may require a slower production speed.

Profile Specifications

Cold roll forming machines can produce a wide variety of profiles,such as C-channels,Z-channels,square tubes,and rectangular tubes.Each type of profile has its own specific specification range.For example,for C-channels,the cross-sectional height commonly ranges from 50mm to 400mm,and the thickness from 1.5mm to 6mm.

Machine Power

The power of the machine varies depending on its scale,degree of automation,and processing capacity.Generally,it ranges from 20kW to 200kW.High-power machines are used for processing thick sheets or for high-speed production.

Maintenance and Servicing Key Points

Daily Cleaning

After each production cycle,it is necessary to promptly remove metal chips,oil stains,and dust from the surface of the machine.Special attention should be paid to cleaning key components such as the rolls in the roll-forming unit,the leveling rolls in the leveler,and the cutting tools in the cutting device.This prevents impurities from wearing the equipment or affecting the quality of the products.Cleaning can be carried out using compressed air blowing,wiping with a damp cloth,or using special cleaning agents.

Lubrication Management

Regularly lubricate all transmission components,such as gears,chains,bearings,and lead screws,according to the requirements of the machine's instruction manual.Select appropriate lubricants and apply them at the specified intervals and dosages.For example,the gearbox needs to have its lubricating oil replaced after a certain number of operating hours,and chains and bearings should be regularly greased.

Component Inspection

Frequently inspect the wear conditions of easily-worn components such as rolls,leveling rolls,and cutting tools.Wear of rolls can affect the forming accuracy of profiles,wear of leveling rolls reduces the leveling effect,and wear of cutting tools leads to poor cut-surface quality.Replace these components in a timely manner when the wear exceeds the limit.At the same time,check whether the bolts and nuts at all connection points are loose and tighten them promptly.

Electrical System Maintenance

Regularly check the electrical wiring to see if there are any signs of aging,damage,or short-circuits.Replace problematic wires in a timely manner.Inspect the electrical components in the control cabinet,such as contactors,relays,and fuses,to ensure good contact and reliable operation.Clean the dust in the control cabinet to ensure good heat dissipation of the electrical components.

Accuracy Calibration

Periodically calibrate the accuracy of the machine,including the flatness calibration of the leveler,the profile size calibration of the roll-forming unit,and the length accuracy calibration of the cutting device.Use professional measuring tools such as calipers,micrometers,and flatness testers for measurement.Adjust the machine parameters or component positions according to the measurement results to ensure stable product quality.