Changeable U purlin roll forming machines are equipment used to continuously form U-shaped purlins from coil steel. Purlins are zinc-coated threaded steel members used in metal building systems to support roof and wall panels.
Changeable U purlin roll forming machines allow switching production between different purlin sizes and thicknesses quickly. This makes them ideal for companies needing flexibility to fulfill varying purlin orders.
Key details about changeable U purlin roll formers:
- Used to form C and Z type purlins from galvanized coil steel
- Changeable roll stands enable quick size changeovers
- Purlin sizes from 2 to 12 inches possible
- Material thickness up to 3 mm
- Forming speeds up to 25 m/min
- Servo motor driven for precision and efficiency
- Touchscreen controls for easy size adjustments
- Robust welded frame construction
Types of Changeable U Purlin Roll Forming Machines
| Machine Type | विवरण |
|---|---|
| Manual Changeover | Requires operator to manually adjust roll stands and guides |
| Hydraulic Changeover | Hydraulic cylinders automatically reposition roll stands |
| Servo Changeover | Servo motors accurately position roll stands |
Manual changeover machines are the most economical option suitable for small workshops with occasional size changes.
Hydraulic changeover systems reduce labor and downtime between runs. Best for frequent changeovers.
Servo changeover offers the highest precision and fastest changeovers but with higher cost. Ideal for high-mix production.
Key Characteristics of Changeable U Purlin Roll Formers
| Characteristic | Details |
|---|---|
| Rolls | Hardened steel rolls form purlins gradually through a series of shaping stations |
| Roll Stands | Adjustable stands house vertically aligned top and bottom rolls |
| Forming Motors | Independent servo or geared motors drive each shaping station |
| PLC Control | Controls forming parameters and stores recipes for each purlin size |
| HMI Touchscreen | Allows easy selection of purlin profiles and monitoring |
| डेकोइलर | Feeds coil stock into roll former at constant tension |
| Guide Box | Straightens strip and guides it through rolls |
| Shear/Punch | Cuts profiles to length and punches bolt holes |
| Conveyor | Transfers finished purlins to exit of line |
Precise roller design, robust framing, and adjustable roll stands are key to producing consistent, high quality purlins across a range of sizes from a single machine. Smart controls make size changes fast and efficient.
Typical Applications of Changeable U Purlin Roll Formers
| आवेदन | Details |
|---|---|
| Metal Building Construction | Primary use is to form purlins for metal building roof and wall systems |
| Structural Framing | Can make steel studs and joists for interior walls, floors, ceilings |
| Solar Mounting Systems | For support structures of ground and roof mounted solar panels |
| Material Handling | Channels, rails, and uprights for conveyors, shelving, racks |
| मचान | Tubes, frames, braces, and rails for scaffold structures |
The ability to produce various purlin sizes makes changeable roll formers ideal for metal building contractors serving many customer segments. The machines can also be utilized for structural framing components and diverse industrial applications.
Design Standards for Changeable Purlin Roll Forming Machines
| Standard | Details |
|---|---|
| चौखटा | Heavy welded steel frame resists vibration and deflection |
| Rolls | Hardened to 55-60 HRC with ground, polished finishes |
| Bearings | Heavy duty SKF or NTN bearings |
| Roll Stands | Adjustable from 2 to 12 inch purlin depths |
| डेकोइलर | Rubberized grippers prevent coil marking |
| न्याय के लिए संघर्ष करनेवाला | 10 roll leveling for consistent flatness |
| Shear | 6000 kN capacity hydraulic end shear |
| Controls | PLC with HMI, servo drives, safety circuits |
| Finishes | Primed then powder coated for durability |
| Safety | Fully enclosed guards, E-stops, light curtains |
| Codes | Designed to AISI, ASTM, ASME, OSHA standards |
Rigid construction, precise machining, quality components, and safe engineering are utilized to produce durable and reliable changeable purlin forming lines.
Specifications of Changeable U Purlin Roll Forming Machines
| विनिर्देश | Details |
|---|---|
| Line Speed | Up to 25 m/min |
| Width Capacity | 650 – 1300 mm |
| मोटाई | 0.5 – 3 mm |
| Purlin Depth | 50 – 300 mm |
| Hole Punching | Optional on some models |
| Power Requirements | 25 – 60 kW |
| Line Length | 15 – 25 meters |
| Machine Weight | 8,000 – 15,000 kg |
Speed, width, thickness ranges, and power requirements vary across manual, hydraulic, and servo changeover machines. Longer lines with decoiler and shear optimize production efficiency.
Suppliers and Pricing of Changeable U Purlin Roll Formers
| Manufacturer | Starting Price |
|---|---|
| Metform | $120,000 |
| Samco | $140,000 |
| Hillary | $100,000 |
| Lingzhong | $90,000 |
| Jinqiu | $110,000 |
Prices range from around $90,000 to $140,000 depending on features. Chinese manufacturers offer lower prices but US brands often have better technical support. Installation and shipping add 10-20%.
Installation and Commissioning of Changeable U Purlin Roll Formers
| Task | Details |
|---|---|
| Site Preparation | Level concrete foundation, remove obstructions |
| Lifting | Use proper rigging to lift sections into place |
| Alignment | Align and bolt frame sections precisely |
| Wiring | Connect power and control wiring |
| Components | Install decoiler, leveler, shear per instructions |
| Trial Run | Inch machine slowly checking alignment, settings |
| Production Run | Ramp up to full speed monitoring quality |
| Training | Review operating and safety procedures |
Proper installation is crucial for smooth production. Technicians supervise on-site activities and test thoroughly before release to operators.
Operation and Maintenance of Changeable U Purlin Roll Formers
| Activity | Frequency |
|---|---|
| Safety Checks | Daily |
| Coil Loading | As needed |
| Size Changeover | As needed |
| Forming Adjustments | As needed |
| स्नेहन | Weekly |
| Inspections | Monthly |
| Bearing Replacement | Annually |
| Roll Regrinding | Annually or as needed |
| Hydraulic Service | Annually |
| Drive Alignment | Annually |
Daily safety procedures must be followed. Operators adjust size changes and monitor quality. Regular maintenance activities sustain performance.
Choosing a Changeable U Purlin Roll Forming Machine Supplier
| Consideration | Guidance |
|---|---|
| Reputation | Choose an established company with proven equipment |
| अनुभव | Look for expertise in the purlin industry |
| Customization | Supplier should customize to your needs |
| Support | Ensure supplier provides installation help, training, and service |
| Cost | Balance purchase price with quality and support |
| Delivery | Confirm supplier can deliver on schedule |
Selecting the right supplier is crucial. Seek combination of domain expertise, customization, responsive support, and reasonable cost.
Advantages of Changeable U Purlin Roll Forming Machines
- Flexibility to produce varying purlin sizes from one machine
- Faster changeovers between sizes
- Precision formed purlins with consistent quality
- High productivity for mass production
- Capability for prototypes and short runs
- Lower capital cost versus dedicated machines
- Efficient utilization of facility and labor
- Scalability to increase output as needed
- Less downtime for size changeovers
- Smooth integration into metal building assembly lines
Key benefits include flexibility, efficiency, quality, and scalability. The machines help metal building contractors fulfill orders of any size.
Limitations of Changeable U Purlin Roll Forming Machines
- Not as specialized as dedicated purlin machines
- Additional maintenance needed from frequent changeovers
- Production speeds may be slower than dedicated lines
- Limitations on very large or very small purlin sizes
- Initial operator training required for changeovers
- More controls expertise needed for setup
- Increased complexity from changeover mechanisms
- Hydraulic or servo changeover adds cost
- Manual changeover takes more time
The main limitations relate to the inherent tradeoffs between dedicated and changeable roll formers.
Cost Comparison of Changeable vs Dedicated Purlin Machines
| Machine Type | Typical Price | लाभ | Disadvantages |
|---|---|---|---|
| Changeable | $90,000 – $140,000 | Flexibility, scalability, moderate cost | Slower, more maintenance |
| Dedicated | $200,000 – $300,000 | Maximum speed and quality | Fixed to one purlin size |
While dedicated purlin machines can maximize productivity and quality for a given profile, changeable machines offer greater flexibility at a lower initial capital cost.
Choosing Between Manual vs Powered Changeover Machines
| Considerations | Manual | हाइड्रोलिक | Servo |
|---|---|---|---|
| Initial Cost | Lowest | Moderate | Highest |
| Changeover Time | Slowest | Fast | Fastest |
| Precision | Lower | अच्छा | उत्कृष्ट |
| Maintenance | Basic | More intensive | Most intensive |
Manual changeover minimizes cost but takes more time. Powered options cost more but boost uptime. Evaluate tradeoffs based on changeover frequency and precision needed.
Common Problems with Changeable U Purlin Roll Forming Machines
| Issue | Solution |
|---|---|
| Inconsistent forming | Check roll alignment and gap settings |
| Profile distortion | Adjust forming pressures and support rolls |
| Roll marking | Increase roll hardness or radius |
| Excess vibration | Tighten loose bolts; realign components |
| Hydraulic leaks | Replace worn seals and hoses |
| Electrical faults | Check wiring; replace damaged cables |
Troubleshooting forming issues, vibration, leaks, electrical faults ensures optimal performance. Precision roll maintenance is also key.
सामान्य प्रश्न
Q: How long does it take to changeover to a different purlin size?
A: Manual changeover can take 1-2 hours. With powered options, the process is usually less than 30 minutes.
Q: Can one machine make both C and Z purlins?
A: Yes, common changeable roll formers can produce both C and Z profiles. Quick change tooling further optimizes changeover.
Q: What thickness of material can the machines accommodate?
A: Standard changeable purlin machines handle 0.5 mm to 3 mm thickness. Extended ranges are possible for specialized applications.
Q: Can the machines add punching and shearing?
A: Many come with punching and shearing standard. These can be added as options if not included.
Q: How long is a typical purlin production line?
A: The full line with decoiler, leveler, roll former, shear is 15-25 meters long depending on features.
Q: What safety features are included?
A: Safety features will consist of e-stops, guards, interlocks, light curtains, and control reliability per norms.
Q: What is the warranty period offered?
A: Most suppliers offer a 12 month warranty. Extensions may be purchased for critical components.
Q: What is the estimated lifetime of the equipment?
A: With proper maintenance, 15-20 years of productive life can be expected from a changeable purlin roll former.