Cassette roll forming machine in the USA

Cassette roll forming machines are versatile and modular systems designed for producing a variety of profiles by utilizing interchangeable cassettes. These machines are particularly popular in industries requiring multiple profile designs, such as construction, automotive, and storage solutions. By swapping out cassettes, manufacturers can achieve different profiles without the need for multiple machines, saving space, time, and costs.

Cassette roll forming machines are robustly built to handle high volumes of production with precision, ensuring consistent quality across all profiles. They are ideal for producing items such as wall panels, roofing sheets, door frames, tracks, and trims.

Specifications

1. Roller Materials:
   • Material: High-quality GCr15 steel or chromium-coated steel for durability and wear resistance.
   • Hardness: HRC 58-62 for long-lasting performance.
2. Frame Size:
   • Solid steel frame with a thickness of 20-30mm for stability during operation.
   • Modular design to accommodate cassette swaps efficiently.
3. Motors and Drives:
   • Main Motor: 7.5 kW - 15 kW (depending on the profile and material gauge).
   • Servo Motor: For precision feeding and punching operations.
   • Hydraulic Station Motor: 5.5 kW for cutting and punching systems.
4. Punching and Notching:
   • Hydraulic punching system with interchangeable dies for different profile requirements.
   • CNC-controlled notching for high accuracy.
5. Cutting System:
   • Hydraulic cutting with hardened steel blades for clean cuts.
   • Optional flying cut-off system for continuous production.
6. PLC Control System:
   • Brand options: Siemens or Mitsubishi PLC for high reliability.
   • Touchscreen interface for easy operation and profile adjustments.
   • Remote control capability for troubleshooting and updates.
7. Machine Speed:
   • Standard: 15-20 m/min.
   • High-speed options: 30-50 m/min, depending on material and profile complexity.
8. Safety Features:
   • Emergency stop buttons at multiple locations.
   • Safety enclosures and light curtains for operator protection.
9. Power Supply:
   • Customizable for U.S. standards (e.g., 220V, 60 Hz or 480V, 60 Hz, 3-phase).
10. Material Compatibility:
    • Steel, galvanized steel, aluminum, copper.
    • Material thickness: 0.3mm - 1.2mm.
11. Optional Extras:
    • Automatic stackers for finished profiles.
    • Coil car and hydraulic uncoiler with a capacity of up to 10 tons.
    • Remote PLC systems for real-time monitoring and diagnostics.
    • Leveling systems for ensuring flat material feeding.

Setup and Installation Process

1. Site Preparation: Ensure a flat and stable foundation to install the machine securely.
2. Machine Assembly: Install the main machine, hydraulic station, and PLC control cabinet.
3. Cassette Installation: Load the required cassette and align it with the roll forming system.
4. Calibration: Perform test runs and adjust rollers for precision.
5. Operator Training: Provide detailed training for operators to handle cassette swaps and system maintenance.

Maintenance Requirements

1. Regularly clean rollers to prevent material residue build-up.
2. Lubricate moving parts and hydraulic systems according to the manufacturer's schedule.
3. Inspect cassettes for wear and replace them as needed.
4. Update PLC software for optimal performance.
5. Check safety systems regularly to ensure compliance.

FAQs

Q1: What is a cassette roll forming machine?
A1: A cassette roll forming machine is a modular system that allows manufacturers to produce various profiles by swapping out interchangeable cassettes instead of using multiple machines.

Q2: What are the main advantages of a cassette roll forming machine?
A2: Key advantages include versatility, space savings, cost efficiency, and quick profile changes without significant downtime.

Q3: Can this machine handle multiple material types?
A3: Yes, it can process steel, galvanized steel, aluminum, and copper, with thicknesses ranging from 0.3mm to 1.2mm.

Q4: Is the machine compatible with U.S. power standards?
A4: Yes, the machine can be customized for U.S. power requirements, such as 220V or 480V, 60 Hz, 3-phase.

Q5: What maintenance does the machine require?
A5: Regular cleaning of rollers, lubrication of moving parts, cassette inspection, and hydraulic system maintenance are necessary to ensure optimal performance.

Q6: How long does it take to change cassettes?
A6: Depending on operator experience and machine design, cassette changes can take as little as 15-30 minutes.

Q7: What safety features are included?
A7: Emergency stop buttons, safety enclosures, light curtains, and operator training programs are standard.

Q8: Can the machine integrate with existing production lines?
A8: Yes, the PLC system and modular design make integration straightforward.

Q9: Is training provided with the machine purchase?
A9: Most suppliers include operator training as part of the purchase package to ensure safe and efficient usage.

Q10: What is the price range for cassette roll forming machines?
A10: Prices vary based on specifications, optional extras, and manufacturer. Standard machines start around $50,000, while advanced models with high-speed capabilities and extras can exceed $150,000.

This guide offers a comprehensive overview of cassette roll forming machines, tailored to meet the requirements of the U.S. market. For more details, contact your local supplier or reach out to Machine Matcher, a leading distributor for roll forming machines globally.