How to fully refurbish a old roll forming machine

Refurbishing an old roll forming machine can be a cost-effective and environmentally friendly alternative to purchasing a new one. With proper refurbishment, you can extend the lifespan of the machine, enhance its efficiency, and bring it up to modern operational standards.

Step 1: Assess the Condition of the Machine

Before you start the refurbishment process, conduct a detailed inspection to assess the machine's overall condition. Key areas to evaluate include:

• Frame and structure: Check for signs of rust, warping, or damage.
• Rollers: Inspect for wear, deformation, or corrosion.
• Electrical systems: Test the functionality of the motors, wiring, and control panels.
• Hydraulic and pneumatic systems: Examine hoses, valves, and cylinders for leaks or damage.
• Bearings and shafts: Check for misalignment or excessive wear.
• Tooling: Assess the condition of the dies and cutting systems.

Create a comprehensive report documenting all necessary repairs, replacements, and upgrades.

Step 2: Disassemble the Machine

Carefully disassemble the machine to access its components for cleaning, repair, or replacement. This step typically includes:

• Removing the rollers and dies.
• Disconnecting motors, hydraulic lines, and electrical components.
• Disassembling the frame and other structural parts if required.

Label each part for easy reassembly and keep small components organized in labeled containers.

Step 3: Clean All Components

Over time, debris, oil, and rust can accumulate on the machine’s parts. Clean each component thoroughly using appropriate methods:

• Degrease and clean: Use industrial-grade degreasers to remove oil and grime.
• Rust removal: Apply rust-removal solutions or sandblast rusted parts.
• Polish rollers and dies: Use polishing equipment to restore the smooth surface of the rollers.

Ensure all components are dry and free of contaminants before proceeding to the next step.

Step 4: Repair or Replace Damaged Parts

Identify components that can be repaired and replace those that are beyond repair. Focus on:

• Rollers: Re-grind or replace worn rollers to ensure precise profile shaping.
• Bearings and shafts: Replace worn bearings and realign shafts for smooth operation.
• Electrical components: Install new wiring, switches, and control panels if necessary.
• Hydraulic and pneumatic systems: Repair or replace faulty hoses, valves, and pumps.

If custom parts are required, consider outsourcing them to a precision machining service.

Step 5: Upgrade Key Systems

To enhance the performance of your refurbished roll forming machine, consider upgrading key systems:

• PLC Control Systems: Install a modern Programmable Logic Controller (PLC) to improve automation and precision.
• Servo Motors: Replace outdated motors with energy-efficient servo motors for better speed and torque control.
• Hydraulic Cutting Systems: Upgrade the cutting system for more accurate and efficient operations.
• Safety Guards and Enclosures: Add safety features to comply with modern safety standards.

These upgrades can improve the machine’s functionality and productivity, making it competitive with newer models.

Step 6: Reassemble the Machine

Reassemble the machine carefully, ensuring all components are aligned and secured. Use your labeled parts and follow the manufacturer’s manual if available. Pay close attention to:

• Roller alignment to avoid profile inconsistencies.
• Correct connection of electrical and hydraulic systems.
• Tightening of bolts and fasteners.

Once assembled, double-check all connections and ensure that moving parts operate freely.

Step 7: Test the Machine

Conduct thorough testing to ensure the refurbished machine operates correctly. Perform the following checks:

1. Run a trial batch: Test the machine with sample materials to evaluate its performance.
2. Check alignment: Ensure the rollers and dies produce accurate profiles without distortion.
3. Monitor performance: Measure speed, efficiency, and output quality.
4. Inspect safety features: Verify that all safety guards and emergency stop systems are functional.

Address any issues identified during testing before declaring the refurbishment complete.

Step 8: Perform Routine Maintenance

Establish a maintenance plan to ensure the refurbished machine remains in optimal condition. Key maintenance tasks include:

• Regular lubrication of moving parts.
• Periodic cleaning to prevent debris buildup.
• Timely replacement of wear-and-tear components.
• Calibration of rollers and control systems.

Document the maintenance schedule and train operators on proper machine care.

Benefits of Refurbishing a Roll Forming Machine

• Cost savings: Refurbishment is significantly cheaper than buying a new machine.
• Extended lifespan: Proper refurbishment can add years to the machine’s operational life.
• Customization: Upgrades allow you to tailor the machine to your specific needs.
• Environmental impact: Refurbishing reduces waste and conserves resources compared to manufacturing a new machine.

Conclusion

Refurbishing an old roll forming machine is a practical and rewarding process that combines mechanical expertise with modern upgrades. By following the steps outlined above, you can restore your machine to peak performance, ensuring efficient and cost-effective production for years to come. Whether you're a seasoned operator or new to the industry, investing in refurbishment can be a smart move for your business.