Double decker roll forming machine in Nepal

The Double Decker Roll Forming Machine is a versatile piece of equipment designed to produce two profiles on a single machine frame. With its unique structure, this machine offers cost savings, space efficiency, and flexibility for manufacturers who need multiple profiles in limited production spaces. Ideal for roofing sheet production, this dual-profile machine is popular in industries requiring high efficiency without sacrificing quality.

Machine Description

A Double Decker Roll Forming Machine combines the functionalities of two roll forming machines in one frame. It can produce two different profiles (typically trapezoidal and corrugated sheets) by switching between upper and lower decks. This machine is used widely in roofing and cladding production, where multiple sheet profiles are needed for various building projects. Its design eliminates the need for separate machines, saving production floor space and reducing the initial investment for manufacturers.

Key Features

• Dual Profiles: Two separate forming sections (decks) in a single machine to produce different profiles.
• Compact Design: Space-saving structure, as the machine stacks profiles vertically.
• Quick Changeover: Operators can quickly switch between profiles, reducing downtime and enhancing productivity.
• Automation Capabilities: Equipped with PLC control for precision and ease of use.
• Safety: Includes protective guards and emergency stop buttons for enhanced safety.

Specifications

1. Machine Structure
   • Upper and Lower Deck: Two decks configured for different profile types.
   • Frame Material: High-grade, reinforced steel for stability.
   • Forming Stations: Varies based on profile complexity, typically between 12-20 stations per deck.
2. Profile Specifications
   • Material Compatibility: Cold-rolled steel, galvanized steel, PPGI, aluminum (thickness 0.3-0.8mm).
   • Sheet Width: Standard width (1000mm, 1200mm, or 1250mm) with adjustments based on customer needs.
   • Profile Height: Varies with profile type; usually between 10-30mm.
3. Rollers
   • Material: High-quality GCr15 steel, heat-treated for durability.
   • Surface Treatment: Chrome-coated to resist wear and corrosion.
4. Drive System
   • Motor Type: Hydraulic or servo motor, depending on model.
   • Main Motor Power: 5.5-11kW for efficient operation.
   • Hydraulic Power: 4kW for cutting and punching processes.
5. Cutting Mechanism
   • Type: Hydraulic cutting with automatic length measurement.
   • Blade Material: Cr12 steel, hardened for long-term usage.
6. Control System
   • PLC Control: Touchscreen interface for easy operation and precise control.
   • Automation: Programmable settings for cutting length, quantity, and profile switching.
7. Speed and Production
   • Forming Speed: 10-15 meters per minute (varies based on profile type and material thickness).
   • Tolerance: ±1.5mm for precise length cutting.
8. Machine Dimensions and Weight
   • Overall Dimensions: Approximately 8m (L) x 1.5m (W) x 1.4m (H) depending on the design.
   • Weight: 8-10 tons, depending on configuration and additional accessories.

Optional Extras

• Stacker: Automatic stacking system to organize finished sheets.
• Uncoiler: Hydraulic uncoiler for efficient material feeding.
• Remote PLC System: Allows for remote troubleshooting and control.
• Embossing Rollers: For adding patterns to the sheets.

Setup and Installation

Installation involves securing the machine to a stable foundation and connecting power and hydraulic systems. The PLC control system will need to be programmed with the necessary parameters, and operators will require training on machine operation and safety protocols. Maintenance includes regular lubrication of moving parts, inspection of rollers, and checking hydraulic systems for leaks.

Maintenance Requirements

• Daily Checks: Ensure proper lubrication, clean the machine surface, and inspect rollers for wear.
• Monthly Checks: Inspect and tighten all bolts and screws, check the hydraulic system, and ensure PLC settings are up to date.
• Annual Maintenance: Professional inspection of electrical and hydraulic systems, replace any worn rollers, and recalibrate the control system if necessary.

Question and Answer

Q1: What types of profiles can a Double Decker Roll Forming Machine produce?
A1: Typically, this machine is configured to produce two types of profiles, such as trapezoidal and corrugated sheets. However, the profiles can be customized to meet specific customer requirements.

Q2: How does switching between the upper and lower deck work?
A2: Switching between decks is controlled by the PLC system. Operators can select the deck they need to activate, and the machine will switch profiles automatically, reducing manual changeover time.

Q3: Can the Double Decker Roll Forming Machine handle various material thicknesses?
A3: Yes, it is designed to handle a range of thicknesses, typically from 0.3mm to 0.8mm, depending on the material and desired profile.

Q4: Is it possible to use different materials on each deck?
A4: While the machine is generally configured for a specific material on both decks, it can be adapted to handle different materials if required, though this may require additional calibration.

Q5: What safety features are included in the Double Decker Roll Forming Machine?
A5: The machine includes safety guards around moving parts, emergency stop buttons, and automated safety features controlled by the PLC to prevent accidents.

Q6: How long does it take to install and set up the machine?
A6: Installation and setup typically take 2-4 days, depending on the level of customization, factory layout, and operator training requirements.

Q7: What is the typical lifespan of a Double Decker Roll Forming Machine?
A7: With proper maintenance, the machine can operate effectively for over 10 years.

Q8: Is remote troubleshooting available for this machine?
A8: Yes, with a remote PLC system option, manufacturers can diagnose issues remotely, saving time and reducing downtime in case of technical issues.