Лучшая машина для формовки рулонов: Выбор, характеристики, эксплуатация

Roll forming is a metal forming process used to produce long sheets or profiles with constant cross-sections. A профилегибочная машина progressively forms sheet metal or strips through a series of roller dies. The process is versatile, efficient and economical for producing high volumes of standardized parts. This guide provides a detailed overview of roll forming machine types, key components, technical specifications, and best practices for selection, operation and maintenance.

Overview of Roll Forming Process and Machines

Roll forming machines are available in different configurations to produce various profiles and cross-sections. The roller dies bend the material incrementally as it passes through successive stands to gradually shape the profile. The key aspects are:

Типы машин для формовки рулонов

Тип машиныОписание
Одиночный профильProduces single profile constantly
Multi-ProfileSwitchable heads for different profiles
ПортативныйCompact for on-site or mobile operation
ОбычайTailored for special profiles

Components of Roll Forming Machine:

  • Roller dies – Formed into successive stands to gradually bend sheet
  • Forming stations – Houses roller dies for sequential bending
  • Decoiler – Feeds raw coil material into machine
  • Feed mechanism – Controls material feed speed and tension
  • Rollers – Provide support and configure material flow
  • Cutoff device – Cuts finished profiles to length

Roll Forming Machine Specifications

The technical specifications of roll forming equipment determine their capability and production capacity. The key parameters to consider are:

Roll Forming Machine Design Specifications:

Rolling LengthLength of rollers and maximum profile length
Rolling WidthWidth between rollers and maximum material width
Rolling ThicknessThickness range of raw material supported
Станции формовкиNumber of stands for progressive bending
Размер роликаDiameter and width of rollers
Материал роликаSteel, alloy steel etc.
Тип роликаHorizontal, vertical, inclined, pyramid etc.
Тип приводаElectric, hydraulic, servo, combination
Speed RangeMinimum and maximum rolling speed
Система подачиUncoiler, feed rolls, pinch rolls etc.
Cutting ModeShearing, sawing, laser cutting etc.
Инструментальная оснасткаQuick changeover, modular, custom etc.
АвтоматизацияPLC controls, motion controls, sensors etc.

Performance Specifications:

ПараметрТиповые значения
Скорость прокатки10 - 100 м/мин
Уровень производстваUp to 120 m/min
Точность±0.5 mm over 3 m length
ПовторяемостьExcellent due to progressive dies
Отделка поверхностиSmooth, marks possible at cut

Operational Requirements:

Мощность20-100 kW connected load
Air Pressure5-8 bar for pneumatics
Персонал1-2 semi-skilled operators
КосмосLength > 15m. Width > 4m, Height > 3m

The specifications vary widely depending on the profile, materials and production volumes. Custom machines can be built to suit specific requirements.

лучшая валковая формовочная машина
Best Roll Forming Machine: Selection, Specifications, Operation 4

Roll Forming Machine Design and Working

The design aspects and working principle of roll forming machines are:

Machine Structure

  • Heavy base frame for stiffness
  • Overhead support stand for forming stations
  • Inline configuration for material flow
  • Lateral or vertical split housing for accessibility

Роликовые штампы

  • Made of machined alloy steel
  • Mounted on shafts in forming stands
  • Arranged horizontally, vertically or at angle
  • Ground and hardened to close tolerances
  • Quick changeover design for flexible production

Станции формовки

  • House combination of top and bottom rollers
  • Roller shafts mounted on bearings
  • Adjustable roller mounts and spacers
  • Guide rails for precise die positioning

Система подачи

  • Decoiler or sheet feeder at start
  • Servo motors and drives for speed control
  • Pinch rolls for positive grip without slippage
  • Dancer arm for maintaining web tension
  • Anti-wicking rolls to prevent deformation


  • Electric servomotors and drives
  • Hydraulic drives for high torque
  • Precision speed and tension control
  • Independent drives for roller shafts
  • Synchronized using master encoder

Система контроля

  • PLC or industrial PC control
  • HMI touchscreen for interface
  • Roll gap and speed settings
  • Servo drive synchronization
  • Safety interlocks and auto stop

Принцип работы

  • Sheet or coil fed into roller dies
  • Progressive bending occurs in steps
  • Bottom rollers provide counterforce
  • Material exiting with finished profile
  • Cut to length by saws or shears

Through the coordinated motion of the precisely machined roller dies, the strip material is gradually shaped into the desired cross-section by the roll forming process.

Roll Forming Operation

1Coil stock fed into feed rolls
2Material progressively shaped by roller dies
3Bottom rollers provide counterforce
4Profiling achieved incrementally
5Formed section flows through machine
6Cutoff device cuts finished profile

Области применения и обслуживаемые отрасли

Roll formed sections find widespread usage across industries due to their continuous production, lightweight properties, high strength and corrosion resistance.

Application Areas of Roll Formed Products:

Structural profilesRoofing sheets, wall panels, liner trays, studs, joists, beams
Storage productsRacking, shelving, lockers, wardrobes
Furniture partsFrames, enclosures, shelving, legs
Automotive partsTrim, sealing, bumpers, roof rails, tubes
ПриборыPanels, enclosures, wrappers, frames
Воздуховоды ОВКRectangular and spiral ducts
Сельскохозяйственные зданияCladding, roofing, structural frames

Industry-wise Applications

ПромышленностьApplication Products
Строительство зданий и сооруженийCladding, decking, purlins, roofing, doors, railing
Автомобильная промышленность и транспортBody panels, roof rails, seat frames, bumpers
Электротехника и электроникаEnclosure panels, chassis, distribution boxes
Consumer AppliancesWashing machine drums, refrigerator liners, exterior panels
Ventilation and Air ConditioningSpiral ducts and fittings, smoke exhausts
ИнфраструктураGuard rails, lighting poles, sign boards, solar frames
МебельCabinet doors, table legs, shelving, storage racks

Roll formed sections enable lightweight, high strength structures across industrial and commercial applications.

Benefits and Advantages of Roll Forming Process

Roll forming offers significant benefits compared to other forming methods:

Преимущества роликовой формовки

Капитальные затратыLower than stamping or press brakes
Operating CostLow power consumption, minimal wastage
Уровень производстваUp to 10x faster than manual methods
ТрудRequires semi-skilled operators
ПереналадкаRoller dies enable fast profile switches
ГибкостьEasy to change dimensions and materials
ТочностьПоследовательные и воспроизводимые профили
Отделка поверхностиSmooth, bright finish possible
ПрочностьCold forming work hardens the metal
ЛегкийThin and lighter structures possible
Simple OperationsUser friendly controls and automation
БезопасностьWell guarded moving parts

Key factors driving adoption of roll forming include high productivity, flexibility, superior quality, and cost efficiency.

лучшая валковая формовочная машина
Best Roll Forming Machine: Selection, Specifications, Operation 5

Типы профилегибочных машин

Roll forming machines are available in different configurations designed for specific production needs:

Типы машин для формовки рулонов

Longitudinal LineFor high volume panel production
Portable RollformerLightweight and mobile operation
Multi-Profile MachineQuick profile changeover
Double Head RollformerБолее высокие темпы производства
Pyramid TypeBi-directional forming capability
Custom RollformerEngineered for special profiles

Longitudinal Line

  • Inline production line
  • Decoiler, accumulator, forming mills, cutoff
  • Lengths over 25 m
  • Parts warehouse integration
  • For high volume sheet production

Portable Rollformer

  • Compact and movable
  • Trailer or truck mounted
  • For on-site production
  • Flexible positioning
  • Lower capacity

Multi-Profile Machine

  • Computer controlled stations
  • Quick die changeover
  • Multiple pre-loaded profiles
  • For lower volume flexibility

Double Head Rollformer

  • Two side-by-side forming lines
  • Independent speed control
  • Higher production rate
  • Redundancy for uptime

Pyramid Type

  • Bi-directional roller configuration
  • Better support during forming
  • Prevents part twisting
  • For symmetrical sections

Custom Rollformer

  • Engineered for unique profile
  • Special roller design
  • Dedicated production
  • For proprietary sections

The choice depends on the required throughput, profile complexity, changeover needs and production volumes.

How to Choose a Roll Forming Machine

The key factors to consider when selecting a roll forming machine are:

Roll Forming Machine Selection Criteria

Форма профиляDimensional specs, radii, angles
МатериалSteel, aluminum grades and thickness
Уровень производстваHourly or annual volume required
ДлинаMaximum part length needed
ШиринаAvailable working width and space
Инструментальная оснасткаStandard or custom roll dies
Средства управленияEase of programming and settings
Уровень автоматизацииMaterial handling and speed control
Line layoutInline or transverse arrangement
ПроизводительностьSpeed, precision, surface finish
БезопасностьGuarding, emergency stops

Critical Factors

  • Profile drawings with complete specifications
  • Annual or daily production volume
  • Operating shifts per day
  • Raw material type and thickness
  • Accuracy and finish requirements
  • Available space for machine
  • Уровень квалификации оператора
  • Expandability for future

Consulting with roll forming experts is highly recommended when specifying machines for the first time or for large production scale. Getting the requirements right is key to maximizing productivity and total cost of ownership.

Производители оборудования для формовки рулонов

Some of leading global manufacturers of roll forming equipment are:

Основные производители валковых формовочных машин

Группа БрэдбериСША
Gasparini SpAИталия
Ханчжоу Ролл Форминг МашинКитай
Howick Ltd.Новая Зеландия
Robor CorpСША
Rollvis SASwitzerland
Разработка технологических процессов формообразованияИндия

Capacities and Models

  • Production up to 180 m/min
  • Width up to 2.5 m
  • Quick die change modular stands
  • Single, dual and multi-profile machines
  • Standard and custom roll former designs

When sourcing roll forming machines, consider manufacturers offering:

  • Wide model range and customization
  • Local sales and service support
  • Новейшие технологии и возможности
  • Training and maintenance programs
  • Overall life cycle value and TCO

Choosing an established manufacturer can ensure access to service, parts, upgrades and process support throughout the machine lifecycle.

Ценообразование на рулонных формовочных машинах

Цены на рулоноформовочные машины варьируются в зависимости от:

Факторы, влияющие на стоимость

  • Type and size
  • Скорость производства
  • Особенности автоматизации
  • Controls and drives
  • Мощность по толщине материала
  • Проектирование оснастки
  • Manufacturer’s brand and location

Typical Cost Ranges

Тип машиныДиапазон цен
Entry level portable$40,000 to $100,000
Single profile machines$100 000 - $500 000
Multi-profile machines$250,000 to $1 Million
High speed longitudinal lines> $1 Million
Нестандартные валковые формовочные машиныApplication dependent

Additional Cost Items

  • Design engineering charges
  • Tooling cost for profile
  • Shipping and customs
  • Installation and commissioning
  • Training for operators
  • Инвентарь запасных частей

Large production lines with warehouse integration, automation and custom features can cost over $2 million. Getting quotes from different vendors is advised.

лучшая валковая формовочная машина
Best Roll Forming Machine: Selection, Specifications, Operation 6

How to Operate and Maintain Roll Forming Machines

Proper operation and preventive maintenance are essential for productivity and longevity of roll forming machines:

Эксплуатация рулонных формовочных машин

PlanningSchedule production, ensure material availability
ИнспекцияCheck rollers, safety devices, lubrication
ПрограммированиеInput correct profile, speed, length
Set upPosition guides, inserts, cutoff
Jog modeInch to test run slower speed
РаботаMonitor forming, speed, sensors
КачествоVerify first piece dimensional accuracy
БезопасностьEnsure guards in place, no unsafe conditions
  • Wear gloves and eye protection when handling sheet metal
  • Adjust machine parameters gradually and systematically
  • Clean oil spills immediately to prevent slips
  • Report any abnormal noise, vibration or behavior

Maintenance Checks

СистемаЗадачи технического обслуживанияЧастота
РоликиInspect surface damageЕженедельник
ПодшипникиLubricate roller shaft bearingsЕжемесячно
ПриводыCheck belt tension and alignmentЕжемесячно
GuardsEnsure in place and functionalЕжедневно
ГидравликаCheck oil level and leaksЕжемесячно
ElectricalInspect connections, coversЕжеквартально
СтруктураCheck loose fastenersЕжемесячно
БезопасностьTest emergency stops and sensorsЕжеквартально

Proactive maintenance as per manufacturer’s recommendations is vital for maximum uptime and extending machine life. Keep records of all inspections, repairs and parts replacements.

Советы по безопасности при прокатке

Roll forming operations involve moving machinery and sheet metal handling which require safety measures:

  • Restrict access for only trained personnel
  • Ensure proper machine guarding is in place
  • Never reach into unsafe areas during operation
  • Выполните процедуры блокировки перед обслуживанием
  • Wear cut resistant gloves when handling sheet metal
  • Keep work area clean and uncluttered
  • Never stand in line with material flow path
  • Maintain adequate lighting in the production area
  • Know emergency stop button locations
  • Report any unsafe electrical, mechanical or hydraulic conditions
  • Never modify or override safety mechanisms
  • Formalize safety procedures and training

Making safety a priority protects personnel and equipment during roll forming operations.

Roll Forming Machine Troubleshooting

Some common issues faced in roll forming machines and remedies are:

Roll Forming Problems and Solutions

ВыпускВозможные причиныКорректирующие действия
Inaccurate profileWorn rollers, loose shaftsRealign/replace rollers, tighten shafts
Scratched finishDebris, damaged rollersClean rollers, replace damaged ones
Чрезмерная вибрацияImbalance, loose partsTighten loose parts, rebalance rollers
Утечки в гидравлической системеWorn seals, damaged hosesReplace seals, damaged hoses
Speed variationSlipping belts, sensor issueAdjust belt tension, check sensor
Uneven material feedWorn/slippery feed rollsReplace feed rolls, increase tension
Замятие листаMisaligned guides, worn rollersRealign guides, replace worn rollers

Consult the machine manual and manufacturer if faults cannot be resolved. Stop operation immediately in case of any safety issues.

Roll Forming Machine FAQs

В: Какие материалы можно подвергать рулонной формовке?

A: Most ductile metals like steel, stainless steel, aluminum, copper, brass. Thickness under 3 mm is common.

Q: What profile shapes are possible?

A: C, U, Z, hat, tube, angle, channel, rails, bars etc. Complex beads and louvers also possible.

Q: How to calculate production rate?

A: Production rate in ft/min = Machine speed (ft/min) x Number of heads

Q: What tolerances are achievable?

A: +/- 0.5 mm over 3 m length is typical. Tighter tolerances possible with precision rollers.

Q: How many operators are needed?

A: 1-2 operators for typical operation. Automated lines may need none.

Q: Is surface coating possible after roll forming?

A: Yes, powder coating and other finishes can be applied after roll forming.

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