Roll forming machine for the production of C-, Z- and Σ-profiles
from € 700.000,-
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C, Z and Sigma profiles can be seen everywhere in buildings, both commercial and non-residential and residential. These profiles were once started with limited dimensions but there has naturally been development in this.
For roll forming, the nice thing about these profiles is that they are tremendously similar.
- The C-profile is the foundation.
- To make a Z-profile, one side of the C is rolled on the other side. This is often solved by double rolls where only at the beginning the material is pushed in the correct bending direction.
- The Sigma profile is the same as a C-profile, but here an additional back, in the form of a trapezoid, is rolled beforehand in the middle.
All these profiles also need holes that are used in construction to mount these profiles together with heavy bolts. This also means punching holes in the profiles. This can be done before roll forming, but many holes can also be punched after roll forming.
General features of the machine
The arrangement of this role-forming line is as follows:
Actually, the line always starts with a decoiler and coil carriage for loading the coils.
This is followed by a loop with loop control before the material is fed into the straightener to make it flat. The material always has a curvature because it is supplied in rolls. This curvature must be taken out before punching can be done. When punching, the line can be used as a start-stop feed, but for speed, a separate feed roller is used to punch the holes at the correct positions. A loop is created between punching and roll forming with loop control. Depending on the different profiles, the roll forming machine will need many stations to profile the heavy construction profiles with right angles. A calibration station is placed at the end of the roll forming machine to reverse the rotation in the profile, which occurs particularly with the Z profile. Important for this is that the material quality is always the same.
After roll forming, the profile is truncated. With this type of profile, this is almost always done afterwards, so as not to leave any deflections of the profile at the beginning and end. Trimming can be performed with either fixed shears or flying shears. With fixed scissors, the roller former stops at the correct length to cut. With flying shears, the shears move with the profile during profiling. Once the shears are up to speed and position, cutting is done. Meanwhile, the roll forming machine continues at a constant speed.
After cutting, the profile is collected. There are many different options for this, ranging from manual stacking to automatic robotic stacking, in which the C and Sigma sections are turned around to be stacked together.
As mentioned, there is a huge variety of sizes. In roll forming, the smallest profile and the largest profile determine how the roll forming line is performed. Currently, the profiles are produced up to a width of 400 mm with a material thickness of 4 mm. In the process, the quality of the material is also getting higher and higher. Whereas previously the material was St37, now material S420 and S490 are used, which of course has consequences for the weight and design of the roll forming machine.
The great advantage of roll forming these profiles is that each length is often different with different hole spacings. This is easy to include in the control. In addition, it is often the huge quantities that are needed, making roll forming the most efficient method of producing the profiles.
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