Double Layer Single Sheet Forming Machine Detailed Description
The double layer single sheet forming machine is a professional cold roll forming equipment integrated with automation, high precision and multi-function, mainly used for continuous forming of metal sheets into two different specifications of profiles in one production line. It is widely applied in the field of building materials processing, solving the problem of low efficiency and high space occupation caused by using two single-layer forming machines separately, and becoming the core equipment for metal roofing, wall panel and steel structure processing enterprises.
Product Core Advantages
Compared with traditional single-layer forming machines, our double layer single sheet forming machine has obvious competitive advantages in performance, cost and operation, which can effectively help enterprises reduce production costs and improve market competitiveness.
- Dual-layer Integrated Design: The machine is equipped with two independent forming stations, which can produce two different types of profiles (such as trapezoidal sheets, corrugated sheets, standing seam roof panels) at the same time or separately. It replaces two single machines, saves 50% of the workshop floor space, and greatly reduces the initial investment cost of equipment.
- High Precision & Stable Forming: The forming rollers are made of high-quality alloy steel, processed by precision CNC lathe, quenched and tempered to enhance hardness and wear resistance. The advanced roll forming technology ensures that the formed profiles have smooth surface, no scratches, accurate size (tolerance ≤±0.1mm), and consistent shape, meeting the high standard requirements of building materials.
- Full Automatic Control System: Adopting imported PLC control system and humanized touch screen operation interface, it is easy to set parameters such as forming speed, cutting length and production quantity. The system has automatic counting, fault alarm, emergency stop and other functions, which can realize unmanned operation in the whole process after parameter setting, reducing labor intensity and human error.
- High Efficiency & Energy Saving: The forming speed can reach 8-15m/min, and the continuous production can be realized without frequent shutdown. The main motor adopts energy-saving frequency conversion design, which can adjust the speed according to the production demand, saving 15-20% of electricity compared with ordinary motors. The low failure rate ensures long-term stable operation, and the daily production capacity can reach 5000-8000 square meters (depending on the profile size).
- Safe & Durable Structure: The main frame is made of thickened steel plate, welded by integral seamless welding, with strong bearing capacity and no deformation during long-term operation. The machine is equipped with safety protection devices (such as emergency stop button, protective cover, infrared safety sensor) to prevent accidents during operation. All wearing parts are standardized and easy to replace, extending the service life of the machine to more than 10 years.
- Strong Customization Ability: According to the customer’s specific needs, we can customize the forming station, roller size, cutting mode, voltage, power and other parameters. It can process various metal materials such as galvanized steel sheet, color steel sheet, aluminum sheet, with a material thickness range of 0.3-1.2mm (customizable) and a coil width of 600-1250mm (customizable).
Detailed Structure & Working Principle
1. Main Structure Components
The machine is composed of 7 core components, each part cooperates closely to ensure the smooth operation of the production line, and all components are strictly inspected before leaving the factory to ensure quality and reliability.
- Decoiler: Equipped with manual or automatic decoiler (optional), suitable for metal coils with weight of 1-5 tons. The decoiler has a tension adjustment function to prevent the coil from loosening or jamming during uncoiling, ensuring stable feeding.
- Leveling Device: Composed of multiple leveling rollers, it can automatically eliminate the deformation of the metal coil caused by transportation and storage, make the sheet flat, and lay a foundation for precise forming. The leveling degree is adjustable to adapt to different thicknesses of sheets.
- Feeding System: Adopting precision chain feeding mechanism, with adjustable feeding speed, which is synchronized with the forming speed to ensure that the sheet is fed stably without deviation. The feeding accuracy can reach ±0.05mm, avoiding the problem of uneven forming caused by feeding deviation.
- Double-layer Roll Forming System: The core part of the machine, with two independent forming stations. Each station is equipped with multiple groups of forming rollers, which gradually form the flat sheet into the required profile through step-by-step rolling. The rollers are designed according to the profile shape, and the surface is polished to ensure the smoothness of the profile.
- Cutting System: Adopting hydraulic or pneumatic cutting mode (optional), with automatic fixed-length cutting function. The cutting blade is made of high-speed steel, which is sharp and durable, ensuring clean cutting surface, no burrs, no deformation, and the cutting precision can reach ±0.1mm. The cutting length can be set freely within the range of 1-12 meters.
- PLC Control Cabinet: The “brain” of the machine, integrating control, operation and monitoring functions. The touch screen can display production parameters, fault information, production quantity and other data in real time, and support parameter storage and call, which is convenient for batch production. The control system is compatible with multiple languages (English, Chinese, Spanish, etc.), suitable for global customers.
- Receiving Table: Equipped with a tilting or flat receiving table, with adjustable height, which is convenient for collecting finished profiles. The receiving table is equipped with anti-scratch pads to prevent the profile surface from being scratched, and the finished products are neatly arranged, which is convenient for packaging and transportation.
2. Working Principle
The whole working process is fully automatic, with simple operation steps: first, put the metal coil on the decoiler, adjust the tension; then, the sheet enters the leveling device to eliminate deformation; then, the feeding system sends the sheet to the double-layer forming station, and the forming rollers roll the sheet into two different profiles at the same time; after forming, the cutting system cuts the profiles according to the set length; finally, the finished products are sent to the receiving table, and the whole production process is completed. The machine can realize continuous production, and the operation can be completed by 1-2 workers, which greatly improves production efficiency.
Technical Parameters (Standard Model)
|
Parameter Name
|
Specification
|
Remarks
|
|---|---|---|
|
Material Thickness
|
0.3-0.8mm
|
Customizable up to 1.2mm
|
|
Coil Width
|
600-1250mm
|
Customizable according to profile
|
|
Forming Speed
|
8-12m/min
|
Adjustable by frequency conversion
|
|
Cutting Length
|
1-12m
|
Freely adjustable
|
|
Main Motor Power
|
3-5.5kW
|
Customizable according to demand
|
|
Hydraulic Motor Power
|
3kW
|
For hydraulic cutting system
|
|
Control System
|
PLC + Touch Screen
|
Multi-language support
|
|
Voltage
|
380V 3P 50Hz
|
Customizable (110V/220V/415V)
|
|
Cutting Mode
|
Hydraulic Cutting
|
Pneumatic cutting optional
|
|
Machine Weight
|
2500-4500kg
|
Depends on model and customization
|
|
Certification
|
CE, ISO9001
|
Meet international standards
|
Application Scope
The double layer single sheet forming machine is widely used in the processing of building metal materials, and its products are widely used in various fields such as industry, commerce and residential buildings. The specific application scenarios are as follows:
- Industrial field: Roofs and walls of industrial factories, warehouses, workshops, etc.
- Commercial field: Roofs and exterior walls of shopping malls, supermarkets, exhibition halls, logistics centers, etc.
- Residential field: Roofs of villas, residential buildings, prefabricated houses, etc.
- Other fields: Steel structure engineering, temporary buildings, greenhouses, billboards, etc.
It can process various common profiles, including trapezoidal roof panels, corrugated wall panels, standing seam roof panels, hidden nail panels, etc., and can also customize special-shaped profiles according to customer drawings.
Quality Assurance & After-sales Service
1. Quality Assurance
We have a strict quality control system, from raw material procurement to product delivery, every link is strictly inspected. The main components (such as forming rollers, motors, PLC) are purchased from well-known brands to ensure the stability and reliability of the machine. All machines are tested for 72 hours continuously before leaving the factory, and only after passing the test can they be delivered.
2. After-sales Service
- Warranty period: 1 year for the whole machine, lifelong maintenance.
- Technical support: Professional technical team provides 24-hour online consultation, solves technical problems in time.
- On-site service: If the machine has major faults that cannot be solved online, we will send professional technicians to the customer’s site for maintenance (the cost is borne according to the warranty terms).
- Spare parts supply: Provide long-term supply of standard spare parts, with fast delivery speed, ensuring that the machine can resume operation in a short time.
- Training service: Provide free on-site training for customer operators, including machine operation, parameter setting, daily maintenance and fault handling, until the operators can master the operation skills proficiently.
Packaging & Shipping
To ensure that the machine is not damaged during transportation, we adopt professional export packaging:
- Machine body: Wrapped with stretch film + moisture-proof paper, then packed in a thick plywood case, which is moisture-proof, shock-proof and anti-collision.
- Main components (such as decoiler, control cabinet): Packed in independent wooden cases to avoid collision during transportation.
- Shipping mode: Support sea transportation, land transportation and air transportation (optional). We cooperate with professional logistics companies to provide door-to-door service, and track the transportation status in real time until the machine is safely delivered to the customer’s hands.
We are a professional manufacturer of roll forming equipment with more than 10 years of production experience. Our double layer single sheet forming machine has been exported to more than 50 countries and regions, and has won wide praise from customers for its stable performance, high quality and perfect after-sales service. If you have any needs for the machine, such as customized parameters, quotation, technical consultation, please contact us, and we will provide you with the most suitable solution.
♦ COMPANY PROFILE:
Hebei Xinnuo Roll Forming Machine Co., Ltd., not only produce different types of professional roll forming machines, but also develop intelligent automatic roll forming production lines, C&Z shape purline machines, highway guardrail roll forming machine lines, sandwich panel production lines, decking forming machines, light keel machines, shutter slat door forming machines, downpipe machines, gutter machines, etc.
Advantages of Roll Forming A Metal Part
There are several advantages of using roll forming for your projects:
- The roll forming process allows operations such as punching, notching, and welding to be performed in-line. Labor cost and time for secondary operations are reduced or eliminated, reducing part costs.
- Roll form tooling allows for a high degree of flexibility. A single set of roll form tools will make almost any length of the same cross-section. Multiple sets of tools for varying length parts are not required.
- It can provide better dimensional control than other competing metal forming processes.
- Repeatability is inherent in the process, allowing easier assembly of roll formed parts into your finished product, and minimizing problems due to “standard” tolerance build up.
- Roll forming is typically a higher speed process.
- Roll forming offers customers a superior surface finish. This makes roll forming an excellent option for decorative stainless steel parts or for parts requiring a finish such as anodizing or powder coating. Also, texture or pattern can be rolled into the surface during forming.
- Roll forming utilizes material more efficiently than other competing processes.
- Roll formed shapes can be developed with thinner walls than competing processes
Roll forming is a continuous process which converts sheet metal into an engineered shape using consecutive sets of mated rolls, each of which makes only incremental changes in the form. The sum of these small changes in form is a complex profile.
