Deep Corrugated Roofing Roll Forming Machine Manual | Setup, PLC Controls, Operation & Troubleshooting Guide

Deep Corrugated Roofing Roll Forming Machine Manual

Complete Setup, Operation, Controls and Production Guide

Introduction

This Deep Corrugated Roofing Roll Forming Machine Manual provides a complete guide for safely setting up, operating, and maintaining a roll forming production line used to manufacture deep corrugated metal roofing panels.

This guide explains every stage of machine operation including:

loading steel coils onto the uncoiler
preparing and threading strip through the roll forming machine
aligning entry guides and forming stations
programming panel length and production quantities
operating PLC controls and jog functions
testing hydraulic shear cutting systems
inspecting finished corrugated panels
troubleshooting common production issues

This manual is intended for:

roll forming machine operators
roofing panel manufacturers
metal fabrication companies
steel building manufacturers
maintenance technicians

1. Machine Overview

A Deep Corrugated Roll Forming Machine produces deep corrugated metal roofing sheets from steel coil. The machine progressively forms flat sheet metal into a deeper corrugated profile through a sequence of roll forming stations.

Deep corrugated roofing panels feature larger corrugation depth and greater structural strength compared with standard corrugated panels.

Deep corrugated panels are commonly used in:

industrial buildings
warehouses
agricultural buildings
steel structure roofing systems
cladding systems

Deep corrugated profiles provide:

increased load capacity
better drainage
stronger panel rigidity

Typical Materials Processed

Common materials include:

galvanized steel
galvalume steel
pre-painted steel coil
aluminum coil

Typical Material Thickness

0.30 mm – 1.00 mm

Typical Production Speed

15 – 35 meters per minute

2. Typical Machine Layout

A typical deep corrugated roll forming production line includes:

Hydraulic Uncoiler
Entry Guide System
Roll Forming Stations
Encoder Length Measuring System
Hydraulic Cutoff Shear
PLC Control Panel
Runout Table or Automatic Stacker

Material flow through the machine:

Steel Coil → Entry Guides → Roll Forming Stations → Encoder → Hydraulic Shear → Finished Panels

3. Safety Before Operating the Machine

Operators must perform safety checks before starting production.

Pre-Start Safety Inspection

Before starting the machine ensure:

emergency stop buttons are operational
safety guards are installed
no tools are inside the machine
hydraulic hoses show no leaks
electrical control panels are closed

Required Personal Protective Equipment

Operators should wear:

safety glasses
steel toe boots
gloves for sheet metal handling
hearing protection

Important Safety Rules

never reach between rotating rolls
never remove guards while machine is running
never stand directly in front of moving sheet metal
stop the machine before making adjustments

4. How to Load a Steel Coil onto the Uncoiler

Step-by-Step Procedure

Stop the machine completely.
Retract the uncoiler mandrel.
Lift the coil using a forklift or overhead crane.
Position the coil directly in front of the mandrel.
Slide the coil onto the mandrel.
Expand the mandrel to secure the coil.
Center the coil evenly.
Install hold-down arm if available.
Adjust uncoiler brake tension.

What to Watch For

coil not centered
coil slipping on mandrel
excessive brake pressure
loose mandrel expansion

Improper coil loading may cause strip tracking issues and panel defects.

5. Preparing the Leading Edge of the Coil

Before feeding the strip into the machine the coil edge must be prepared.

Procedure

Carefully remove steel banding.
Control the coil to prevent sudden expansion.
Inspect first 300–500 mm of strip.
Cut away damaged sections.
Square the leading edge using sheet shears.
Remove burrs if necessary.
Confirm paint side orientation.

Why This Step Matters

A damaged strip edge can cause:

feeding problems
roller damage
machine jams
surface scratching

6. Threading the Coil Through the Roll Forming Machine

Procedure

Fully open entry guides.
Feed strip manually into the first roll station.
Ensure strip enters straight.
Use jog mode to slowly pull strip through stations.
Continue feeding through forming stations.
Guide strip through shear section.
Feed strip onto runout table.

Safety Warning

Never place hands between rotating rolls.

Use push tools where necessary.

7. Aligning and Centering the Strip

Proper strip alignment ensures accurate panel formation.

Procedure

Observe strip entering first forming station.
Adjust entry guides left or right.
Ensure strip runs parallel with machine centerline.
Maintain equal clearance between guides.
Run machine slowly to check strip tracking.

Signs of Misalignment

strip drifting sideways
uneven corrugation
panel twisting
panel width variation

8. Complete Deep Corrugated Machine Setup Parameters

Before production begins the machine must be configured correctly.

Material Type: Galvanized / Galvalume / Painted Steel
Material Thickness Range: 0.30 mm – 1.00 mm
Coil Width: Typically 914 – 1250 mm depending on profile
Coil Weight: Up to 5 – 10 tons
Coil Inner Diameter: 450 – 520 mm
Entry Guide Clearance: Coil width + 1–2 mm
Forming Stations: 16 – 22 stations
Machine Speed (Setup): 5 – 10 m/min
Machine Speed (Production): 15 – 35 m/min

Roll Gap Setup

Roll gap should be set to:

Material thickness + 0.05 mm clearance

Example:

Material thickness = 0.60 mm
Recommended roll gap = 0.65 mm

Incorrect roll gaps may cause:

distorted corrugation
surface scratches
incomplete forming

9. PLC Control System Overview

Modern deep corrugated roll forming machines use a PLC control system with touchscreen interface.

The PLC controls:

machine start and stop
panel length programming
panel quantity production
machine speed control
hydraulic shear timing
encoder length measurement

10. PLC Control Panel Functions

Typical PLC functions include:

Start Button – starts machine operation
Stop Button – stops machine safely
Emergency Stop – immediate shutdown
Manual Mode – used for setup and adjustments
Automatic Mode – runs production automatically
Panel Length Setting – sets finished panel length
Panel Quantity Setting – sets production quantity
Production Counter – displays panels produced

11. Jog Mode Operation

Jog mode allows slow machine movement during setup.

Jog Mode Uses

threading strip through machine
aligning strip
positioning strip before cutting

Jog Procedure

Switch machine to Manual Mode
Press Jog Forward
Machine moves slowly
Release button to stop

Some machines include Jog Reverse.

12. Programming Panel Length

Procedure

Open PLC production screen
Enter required panel length
Confirm measurement units
Run test panel
Measure finished panel length
Adjust encoder calibration if required

13. Programming Panel Quantity

Procedure

Enter required panel quantity on PLC screen
Confirm settings
Start automatic production

Machine stops automatically when programmed quantity is reached.

14. Encoder Length Measurement System

Panel length is measured using an encoder wheel contacting the strip.

The encoder converts strip movement into electronic pulses.

Typical Accuracy

±1 – 2 mm

Common Encoder Problems

measuring wheel slipping
debris buildup on wheel
encoder wiring faults

15. Hydraulic Shear Operation

The hydraulic shear cuts panels to programmed length.

Cutting Sequence

Encoder measures programmed length
PLC activates hydraulic valve
Hydraulic cylinder drives shear blade
Panel is cut
Blade returns to starting position

16. Testing the Hydraulic Shear

Procedure

Start hydraulic system
Run machine in manual mode
Activate shear test cycle
Inspect cut quality

Check for:

clean cuts
no burrs
correct blade movement

17. Inspecting Finished Deep Corrugated Panels

Operators must inspect panels during production.

Inspection Checklist

panel length
cover width
corrugation depth
panel straightness
surface finish
cut edge quality

18. Panel Defect Troubleshooting Guide

Operators should monitor panel quality continuously during production.

Panel Twisting

Possible Causes: strip misalignment or uneven roll pressure.

Recommended Solution: adjust entry guides and inspect roll alignment.

Uneven Corrugation

Possible Causes: incorrect roll gap or roll wear.

Recommended Solution: adjust roll gaps and inspect forming rollers.

Surface Scratches

Possible Causes: dirty rollers or debris.

Recommended Solution: clean rollers and entry guides.

Panel Length Variation

Possible Causes: encoder slipping.

Recommended Solution: clean encoder wheel and recalibrate PLC.

Poor Cut Quality

Possible Causes: dull shear blades.

Recommended Solution: sharpen or replace shear blades.

19. Changing Production Speed

Procedure

Start machine at low speed
Observe strip tracking
Increase speed gradually
Monitor panel quality

Typical speeds:

Setup speed: 5 – 10 m/min
Production speed: 15 – 35 m/min

20. Machine Shutdown Procedure

Stop automatic production
Allow final panel to exit machine
Stop drive motor
Turn off hydraulic system
Secure remaining coil
Clean machine area
Record production results

21. Daily Operator Checks

Operators should check:

roll cleanliness
hydraulic oil level
encoder wheel condition
shear blade wear
unusual machine noise
loose bolts

22. Deep Corrugated Roll Forming Machine Technical Specifications

Forming Stations: 16 – 22 stations
Material Thickness Range: 0.30 – 1.00 mm
Production Speed: 15 – 35 meters per minute
Drive System: Gearbox drive or chain drive
Cutting System: Hydraulic stop-cut shear
Control System: PLC control with touchscreen interface
Coil Weight Capacity: 5 – 10 tons
Coil Inner Diameter: 450 – 520 mm
Coil Width: Typically 914 – 1250 mm
Electrical Power Requirement: 380 – 480V three-phase power supply

23. Best Operator Practices

Experienced operators follow these practices:

inspect the first panel carefully
maintain correct strip alignment
monitor machine continuously
keep rollers clean
stop machine immediately if abnormal noise occurs

Proper operation ensures consistent panel quality and long machine life.