Metal sheet roof roll forming machine in Japan

A metal sheet roof roll forming machine is essential for industries involved in producing roofing panels from metal sheets. These machines are designed to transform coiled metal sheets into a specific profile suitable for roofing applications. They are widely used in construction, particularly for commercial, industrial, and residential roofing projects. Their efficiency, precision, and automation make them indispensable in the roofing manufacturing industry.

Machine Description

A metal sheet roof roll forming machine typically operates by feeding a metal coil through a series of rollers that gradually shape the sheet into the desired roofing profile. These profiles vary depending on regional preferences and the specific demands of construction projects. This machine is known for producing high-quality, uniform roofing panels with minimal human intervention.

The roofing profiles created can include trapezoidal, corrugated, and ribbed panels. With automation and PLC control systems, these machines can produce panels of varying lengths to meet specific project requirements. They are also designed to be user-friendly, with safety features to ensure operational safety.

Specifications of a Metal Sheet Roof Roll Forming Machine

Here are the key specifications typically found in metal sheet roof roll forming machines:

1. Roller Material: High-grade steel (usually GCr15 or 45# steel) with surface hardening treatment, providing longevity and durability.
2. Roller Stations: Typically ranges from 12 to 24 stations, depending on the profile complexity and machine length.
3. Profile Width: Common widths include 1000mm, 1200mm, and 1250mm. Customizable for other widths as per requirements.
4. Material Thickness: Can handle metal sheets ranging from 0.3mm to 0.8mm, depending on the specific model and power capabilities.
5. Cutting System: Hydraulic cutting system with high precision. Uses Cr12 or Cr12MoV steel for cutting dies to ensure clean cuts and longevity.
6. Motor Power: Main motor power generally ranges from 5.5kW to 15kW, depending on the production speed and complexity of the profile.
7. Production Speed: Common speeds range between 10 to 30 meters per minute. Higher speeds are available for specific applications.
8. Control System: PLC (Programmable Logic Controller) system with touch screen interface for easy operation and parameter setting.
9. Machine Dimensions: Varies with each model but typically around 8000mm to 12000mm in length and 1000mm in width.
10. Weight: Machine weight can range from 5 to 15 tons, depending on the machine configuration and materials.
11. Coil Loading Capacity: Usually around 5 tons, with a de-coiler to hold and feed the metal coil.
12. Optional Accessories: Uncoiler, stackers, hydraulic pre-shearing, pre-cutting system, and auto-stacker.

Applications

• Construction Industry: Widely used in commercial, industrial, and residential roofing systems.
• Warehouses and Factories: For creating roofing panels to cover large spaces.
• Farm Sheds and Agricultural Buildings: Suitable for rural applications where durability and weather resistance are critical.
• Pre-fabricated Buildings: Often used for roofing panels in modular or pre-fabricated building projects.

Setup and Installation

Setting up a metal sheet roof roll forming machine requires the following steps:

1. Positioning: Place the machine on a stable, level surface in a well-ventilated area.
2. Power Supply: Ensure the power supply meets the machine’s requirements, considering factors like voltage and power stability.
3. Coil Loading: Load the metal coil on the de-coiler, ensuring proper alignment with the machine’s entry.
4. Calibration: Calibrate the machine according to the desired profile and sheet length.
5. Test Run: Perform a test run to check the profile, length accuracy, and machine efficiency.
6. Adjustments: Make necessary adjustments for thickness, width, and other profile settings as needed.

Maintenance Requirements

Regular maintenance ensures smooth operation and long life for metal sheet roof roll forming machines. Here are some critical maintenance tasks:

• Lubrication: Regularly lubricate rollers, bearings, and moving parts to reduce wear and tear.
• Roller Inspection: Inspect rollers for any deformation or damage; replace or repair as needed.
• Cutting System Maintenance: Sharpen or replace cutting dies periodically to maintain clean cuts.
• Electrical System Check: Regularly inspect electrical components, ensuring there are no loose wires or faults.
• PLC System Update: Update the PLC software periodically to optimize performance.

Question and Answer Section

Q1: What materials can be used in a metal sheet roof roll forming machine?

A1: Metal sheet roof roll forming machines commonly work with galvanized steel, aluminum, and color-coated steel. The machine’s specifications determine the range of compatible materials, with thicknesses typically between 0.3mm and 0.8mm.

Q2: How long does it take to produce a single roofing panel?

A2: Production speed varies based on the machine's configuration but usually ranges from 10 to 30 meters per minute. High-speed machines can produce panels faster, while complex profiles may reduce the speed slightly.

Q3: Can I customize the profile shape?

A3: Yes, most roll forming machines can be customized to produce various profiles, including trapezoidal, corrugated, and ribbed panels. Customization is often available at the design stage based on the specific application and regional preferences.

Q4: What is the average lifespan of a metal sheet roof roll forming machine?

A4: With proper maintenance, a metal sheet roof roll forming machine can last between 10 and 20 years, depending on the frequency of use and material quality.

Q5: Do I need any additional equipment to operate this machine?

A5: Additional equipment like an uncoiler, stacker, and auto-stacker can improve efficiency and ease of operation. While these are optional, they are recommended for larger-scale operations.

Q6: Is the machine energy efficient?

A6: Metal sheet roof roll forming machines are generally energy-efficient. The PLC system allows for efficient control over operations, minimizing energy usage and maximizing productivity.

Q7: How do I ensure safety during operation?

A7: Safety features such as emergency stop buttons, safety guards, and enclosures are typically installed. Operators should undergo training on safety procedures, including proper handling of metal coils and emergency protocols.

Q8: What factors should I consider when choosing a metal sheet roof roll forming machine?

A8: Key considerations include the required profile type, material thickness, machine speed, power supply, and space availability in your production area. Additionally, consider whether your operations would benefit from optional accessories like stackers and pre-shearing systems.