Roll forming machines are high-speed production systems with motors, VFDs, encoders, sensors, hydraulic units, cutters, and control panels all working together. When any one of these systems begins to degrade, machine performance suffers — long before a full failure occurs.

Machine Matcher’s Machine Health Monitoring Service detects electrical, mechanical, and performance problems early, allowing you to fix issues before they turn into downtime, tooling damage, or scrap material.

Below is the full breakdown of what is included in our monitoring and diagnostic program.

1. Checking Running Currents vs. Design Currents

One of the most important indicators of machine health is actual motor current versus expected motor current.

Why It Matters

• Identifies overloaded motors

• Reveals bearing wear

• Shows gearbox issues

• Detects VFD parameter problems

• Prevents motor burnouts

• Helps balance production loads

We Measure & Report

• Main roll former drive motor current

• Hydraulic pump motor current

• Decoiler motor current

• Conveyor & stacker motor currents

• VFD output data

If a motor draws 20–40% more current than its design rating, a breakdown is imminent.

2. Full Diagnostic Report on All Machine Electrical Loads

Machine Matcher provides a complete technical condition report covering all critical systems.

Motor Load Analysis

We measure:

• Actual load % versus rated load

• Current spike behaviour

• Starting load profile

• Torque stability

• VFD efficiency

This allows us to detect mechanical resistance before it becomes failure.

Shear Load Measurement

Cutting load is the best early-warning sign for:

• Blunt shear blades

• Mechanical resistance

• Misalignment

• Hydraulic weakness

• Cylinder leakage

• Low-pressure conditions

We compare shear motor or hydraulic load against expected values.

Encoder Pulse Quality

A healthy encoder produces:

• Clean square-wave pulses

• Stable frequency

• Zero signal dropouts

• Correct direction

We measure:

• Pulse stability

• Noise levels

• Missing counts

• Drift or slippage

• Response under high speed

Encoder issues cause:

• Incorrect cut length

• Mis-punching

• Scrap material

• Inconsistent production

Cabinet Temperature Monitoring

Overheating control cabinets lead to:

• VFD failures

• Power supply shutdown

• Sensor malfunction

• PLC resets

• Thermal drift

• Shortened component life

We check:

• Internal temperature rise

• VFD and power supply heat levels

• Fan performance

• Filter condition

• Cabinet cooling requirements

Sensor Reaction Time Testing

Slow or unstable sensors cause:

• Mis-cuts

• Mis-punching

• Slow cycle times

• Alarms and machine stops

We test:

• Sensor activation speed

• Reaction timing accuracy

• Signal noise

• Light interference

• Proximity sensor range

• Inductive sensor stability

Even 10–30 ms of delay can create production errors.

Panel Wiring Condition Inspection

A detailed inspection covers:

• Loose terminals

• Oxidized or burnt contacts

• Undersized cables

• Overloaded breakers

• Broken ferrules

• Poor shielding

• Weak grounding

• Unsafe modifications

Most machines older than 3–5 years require wiring improvements to maintain reliability.

3. Recommended Upgrades & Preventive Actions

After completing full machine monitoring, Machine Matcher provides:

Customized Upgrade List

• VFD parameter optimization

• Encoder replacement or recalibration

• Sensor upgrades (faster, more stable models)

• Cabinet cooling fans or heat exchangers

• Line reactors for VFD protection

• Surge protection installation

• Grounding/bonding improvements

• Control panel rewiring

• Breaker segregation upgrades

• Hydraulic load balancing

We also outline:

• Immediate fixes

• Medium-risk issues

• Long-term improvements

• Estimated costs

• Expected ROI based on reduced downtime

4. Why Machine Health Monitoring Matters

Factories using Machine Matcher’s monitoring program experience:

• 40–70% reduction in electrical failures

• Up to 60% improved motor lifespan

• Fewer cut-length errors & scrap

• Better machine speed consistency

• Longer tool life

• More predictable maintenance scheduling

• Instant identification of weak components

Your machine becomes more reliable, safer, and easier to maintain.

Machine Matcher CTA — Book a Machine Health Monitoring Service

Our technicians provide:

• On-site monitoring

• Full electrical performance report

• Motor & shear load analysis

• Encoder & sensor diagnostics

• Panel inspection

• Upgrade recommendations

• Preventive maintenance plan

• 24/7 remote support

Protect your machine. Prevent downtime.

Book your Machine Health Monitoring inspection today.

Machine Matcher now offers full electrical technician services for roll forming machines — including diagnostics, rewiring, testing, encoder calibration, PLC programming, electrical audits, and preventive maintenance.
We support all machine types and all global regions.
Contact us today for immediate technical assistance or to schedule a full electrical inspection at your factory.

Looking for the right roll forming machine or expert guidance on your next project? Machine Matcher is here to help. Our global team provides 24/7 technical support, expert advice, and guidance on machine selection, setup, and maintenance—ensuring your operations run smoothly from day one.

With team members based worldwide—including the UK, USA, Middle East, and beyond—we are equipped to assist buyers across the globe. Whether you’re sourcing a single machine or upgrading an entire production line, our experts are ready to provide tailored solutions and support every step of the way.

Get in touch now and let Machine Matcher help you find the perfect roll forming machine for your business.

United Kingdom (Main Office)
Phone: +44 20 335 56554

United States
Phone: +1 407 559 7948

Mobile / WhatsApp: +44 7816 972935

Email: [email protected]