Steel stud roll forming machine in Nepal

A steel stud roll forming machine is a specialized industrial machine designed to produce steel studs and tracks, which are commonly used in the construction industry for creating wall partitions, ceilings, and other structural frameworks in both commercial and residential buildings. The machine uses a series of rollers to shape a continuous strip of metal into precise, high-quality steel studs and tracks. Steel studs made by these machines are widely used due to their strength, durability, and ease of installation, making them a preferred alternative to traditional wooden framing.

Specifications

1. Roller Material: High-grade chromium or GCr15 steel to withstand wear and maintain precision over long production runs.
2. Roller Stations: 10–20 stations (customizable based on required stud profile and size) for gradual shaping of steel strips into precise stud profiles.
3. Profile Size: Can produce standard stud sizes such as 35mm, 45mm, 65mm, 90mm, and 140mm, along with custom profiles depending on market requirements.
4. Material Thickness: Typically works with steel gauges between 0.6 mm to 1.2 mm, though this can be adjusted based on the specific machine model.
5. Motor Power: Ranges from 7.5 kW to 15 kW to ensure steady production speed and energy efficiency.
6. Cutting System: Hydraulic cutting system with automatic length measurement for precision cutting without stopping the line. This system includes a cutting die made from hardened steel for long life.
7. Machine Speed: Production speed usually varies between 30 to 60 meters per minute, depending on the complexity of the stud profile.
8. PLC Control System: Uses an advanced PLC (Programmable Logic Controller) system with an HMI (Human-Machine Interface) touch screen for easy operation and precise adjustments.
9. Safety Features: Includes safety guards, emergency stops, and sensors to detect material jams, ensuring safe operation for the operator.
10. Dimensions and Weight: Customizable based on production requirements; average machines weigh around 6–8 tons and measure approximately 8–10 meters in length.
11. Power Supply: Options available for various power requirements, including 380V/50Hz for international standards or other custom voltages as required.
12. Additional Features: Optional add-ons such as stackers, punching and notching units, and automatic coil handling systems can be included for enhanced functionality.

Question and Answer Section

1. Q: What are the main materials used to manufacture studs with this roll forming machine?
   A: The machine can process various metals, primarily galvanized steel and other steel alloys that meet the thickness requirements. Galvanized steel is the preferred material for its resistance to corrosion, strength, and cost-effectiveness in construction.
2. Q: How does a Steel Stud Roll Forming Machine ensure the accuracy of the studs?
   A: The machine utilizes a series of high-precision rollers made from durable steel. Each roller station gradually forms the metal to reduce stress on the material and maintain shape consistency. Additionally, the PLC system controls and monitors the speed, cutting length, and other settings to maintain tight tolerances.
3. Q: Can the machine create custom stud profiles?
   A: Yes, many steel stud roll forming machines are customizable to produce various profiles. If a specific profile is required, the roller stations can be designed accordingly, allowing the machine to manufacture unique stud sizes or shapes as needed.
4. Q: What are the benefits of using a Steel Stud Roll Forming Machine over traditional manufacturing methods?
   A: This machine offers several advantages, including high-speed production, uniform quality, reduced material waste, and cost savings in labor. It also allows for continuous production, which can increase output and efficiency compared to other methods.
5. Q: What is the typical maintenance required for a Steel Stud Roll Forming Machine?
   A: Regular maintenance includes checking and lubricating rollers, inspecting and sharpening the cutting blades, and verifying the PLC system's accuracy. Regular cleaning, along with timely repairs, can extend the machine’s lifespan and improve performance.
6. Q: Are there different sizes of Steel Stud Roll Forming Machines?
   A: Yes, machines are available in various configurations, depending on production needs, such as different profile sizes, thickness capabilities, and speeds. Manufacturers can also customize the machine’s layout to accommodate different factory space requirements.
7. Q: Can the machine be operated by a single person?
   A: While the machine is user-friendly and can be managed by a single operator, it is recommended to have additional personnel for tasks like material loading and unloading, quality inspection, and maintenance checks.
8. Q: Is it possible to integrate automation systems with this machine?
   A: Absolutely. Many steel stud roll forming machines support optional automation systems, such as automatic stackers and remote PLC control. These additions can streamline production and reduce manual labor further.
9. Q: What safety features are included?
   A: Safety features include emergency stop buttons, safety guards around moving parts, and sensors to detect any abnormalities, such as material jams or power fluctuations. These systems help prevent accidents and protect operators.
10. Q: How long does it take to install a Steel Stud Roll Forming Machine?
    A: Installation typically takes 2-4 days, depending on the complexity of the machine and available site facilities. A team of technicians can handle the setup and ensure the machine is correctly calibrated for production.