Door frame roll forming machine in Hong Kong

Door Frame Roll Forming Machine: Full Description and Specifications

Introduction

A door frame roll forming machine is an essential piece of equipment in the construction and manufacturing industries, specifically designed for fabricating metal door frames. These frames are used in residential, commercial, and industrial applications, offering a durable, uniform, and precise option for framing doors. Roll forming is an efficient process that shapes metal coils into the required door frame profile through continuous bending operations.

Machine Description

The Door Frame Roll Forming Machine transforms metal coils into door frame profiles with consistent quality and precision. It operates by feeding the metal coil through a series of rollers, each gradually shaping the metal to form a complete door frame profile. This machine is typically used for mass production due to its high speed, minimal waste, and efficiency in producing door frames in various sizes and specifications.

Specifications

• Roller Materials: High-quality Cr12MoV steel, hardened for durability and precision.
• Punching and Notching: Equipped with hydraulic punching and notching stations for creating holes, cut-outs, and slots in precise locations for hinges, locks, and other fittings.
• Servo Motors: Advanced servo motors control the feeding and punching, ensuring accuracy and consistency in production.
• Hydraulic Cutting System: A high-strength hydraulic system ensures precise cutting of frames to the desired length without deforming the profile.
• Frame Size: The machine structure is typically robust, with frame dimensions tailored to handle both heavy and light-duty applications, allowing for versatility.
• Motors and Power Requirements: High-power motors, generally ranging from 5 to 10 HP depending on the machine's capacity, ensure efficient operation.
• PLC Control System: Automated control via a PLC (Programmable Logic Controller) enables easy adjustments, error detection, and real-time monitoring.
• Machine Speed: Production speeds can range from 10 to 30 meters per minute, adjustable based on material thickness and profile complexity.
• Safety Guards and Enclosures: Safety features are integrated to protect operators, including covers for moving parts and emergency stop mechanisms.

Profile Description

• Materials: Commonly used materials include galvanized steel, stainless steel, and aluminum. These materials provide durability, resistance to corrosion, and a professional finish.
• Sizes: Customizable to produce a range of frame widths and depths suitable for various door applications, typically adjustable within 50–200mm in width and 10–50mm in depth.
• Material Gauge: Supports materials ranging from 0.5mm to 2.0mm in thickness.
• Market Size and Industries: Widely used in construction for residential, commercial, and industrial door frames.
• Popular Countries: High demand exists in the United States, Canada, Europe, the Middle East, and Southeast Asia due to the construction industry's growth in these regions.

Optional Extras

• Stackers: Automatic stackers collect and organize finished profiles, enhancing productivity and reducing manual handling.
• Remote PLC Systems: Enable remote monitoring and adjustment, ideal for large-scale production environments.
• Coil Car Tippers and Uncoilers: Facilitate efficient coil handling, reducing downtime and improving workflow.

Setup and Installation

Setting up a door frame roll forming machine involves preparing a stable foundation, connecting the machine to an appropriate power source, and calibrating the rollers for the desired profile specifications. Technicians usually guide the installation and initial testing to ensure optimal machine performance.

Maintenance Requirements

Routine maintenance includes lubrication of rollers, inspection of the hydraulic system, checking motor functionality, and calibration of the PLC controls. Regular maintenance ensures longevity, high-quality output, and minimizes the risk of downtime.

Question and Answer Section

Q1: What types of metal can be used with a door frame roll forming machine?
A1: Door frame roll forming machines are versatile and can typically process galvanized steel, stainless steel, and aluminum. The choice depends on the end-use application and required strength or corrosion resistance.

Q2: Can the machine produce custom door frame profiles?
A2: Yes, these machines are designed to be adjustable for various profile widths, depths, and thicknesses. Custom dies and rollers can be created to fit specific profile designs.

Q3: How fast can a door frame roll forming machine produce frames?
A3: Production speeds vary but generally range from 10 to 30 meters per minute, depending on factors like material thickness and profile complexity. Higher-end models may offer even faster speeds.

Q4: Is a door frame roll forming machine suitable for large-scale production?
A4: Absolutely. The machine’s high speed, consistency, and minimal waste make it ideal for large-scale production in construction, commercial, and industrial applications.

Q5: What are the maintenance requirements?
A5: Regular maintenance is essential to ensure optimal performance and longevity. This includes lubricating rollers, inspecting hydraulic components, checking motor health, and calibrating the PLC control system.

Q6: Are there safety features integrated into the machine?
A6: Yes, most door frame roll forming machines include safety guards around moving parts, emergency stop buttons, and enclosures to protect operators from accidental contact with the machinery.

Q7: Can I integrate additional features like punching or notching?
A7: Many machines come with hydraulic punching and notching stations, allowing for customized slots, holes, and cut-outs necessary for hinges, locks, and other fittings directly during the roll-forming process.

Q8: How does the PLC system benefit production?
A8: The PLC system automates production, allowing for easy adjustments, error detection, real-time monitoring, and consistency across all door frame profiles. It also enables remote operation if paired with a remote PLC system.

Q9: What are some optional extras, and how do they enhance production?
A9: Optional extras include stackers, remote PLC systems, coil car tippers, and uncoilers. These add-ons increase efficiency by automating parts of the process like profile collection, remote operation, and material handling, which can reduce labor costs and speed up production.

Q10: What are the space requirements for installing this machine?
A10: The space requirements depend on the machine’s frame size and the workflow setup. Typically, a large, stable area with enough room for raw material storage, machine installation, and finished product collection is recommended.