Overview of c section c frame roll forming machine

C section C frame roll forming machines are used to produce structural steel members with a C-shaped cross section for the construction industry. The C section profiles provide excellent strength for framing applications.

This guide covers C frame roll former working principles, main components, specifications, production line configurations, tooling accessories, applications in construction and pre-engineering building, benefits, top manufacturers, cost analysis, purchasing considerations, maintenance tips and FAQs.

Working Principle of C Frame Roll Forming

The operating sequence of a C section C frame roll forming line is:

• Coil of steel sheet loaded into the de-coiler
• Sheet enters leveler machine for initial flattening
• Leveled sheet fed into the entry guides
• Sheet passes through sequential rolling stations
• Forming rollers gradually bend the steel sheet into C shape
• Finished C section exits on to the cutting table
• Cutter shears the profile to desired length
• Conveyor stacks cut parts for bundling
• Hydraulic motors coupled to gearboxes drive the roll stations
• PLC automated control synchronizes the components

The gradually bending steps produce uniform C sections with excellent surface finish and dimensional accuracy.

Main Components of C Frame Roll Former

Key components of a C section C frame roll forming machine include:

• De-coiler – Holds and feeds the steel coil
• Feeder – Feeds sheet into the line
• Leveler – Flattens sheet prior to forming
• Roll forming stations – Bend sheet in steps
• Roll tooling – Machined to C profile shape
• Cutting unit – Shears cut profiles to length
• Stacking table – Collects finished C sections
• Bundling system – Straps cut parts into bundles
• Electrical controls – PLC, HMI, AC drives
• Safety guarding – For operator protection

Precisely aligned components produce uniform, quality C sections.

Specifications of C Frame Roll Formers

Typical specifications of C frame roll forming machines:

Larger roller diameters allow forming heavier material. More powerful motors yield higher production rates.

Types of C Frame Sections Produced

Common C frame section sizes produced on these roll formers:

• C purlins – 100 to 300 mm
• Metsec Metric C sections – 2MC to 14MC
• A/HBox beams – All standard sizes
• Miscellaneous – Custom C profiles

Quick roll change systems allow various C section sizes to be interchanged easily.

C Frame Roll Former Configurations

Typical C frame roll former line configurations:

• Compact – Entry guides to cutter in one frame
• Modular – Separate modules bolted together
• In-line – Straight from one end to other
• L-shaped – Saves space
• Double decoiler – For quick coil change
• Closed-loop – Exits to coiler side
• Servo-electric – Precision servo motor drives
• Custom – Tailored layouts to needs

Layouts are designed to optimize material flow, space and production requirements.

Tooling Accessories for C Frame Rollers

Tooling enhancements for C frame roll forming machines:

• Quick change – Fast roll set swaps
• Punching – Hole punching attachment
• Embossing – Pattern rolls for decorative finishes
• Notching – Edge notching attachment
• Bending – Rails for bending into arcs
• Double sheet – Split rolls for dual sheets
• Roll protection – Guards against damage
• Roll ramps – Ease feeding of thick sheets
• Roll levellers – Ensure concentricity

Tooling expands the range of profiles and features possible.

Applications of C Frame Sections

Typical applications of C frame profiles:

• Roof joists – Rafters, purlins, eaves
• Wall studs – External and internal framing
• Structural supports – Columns, braces
• Mezzanine flooring – Platforms, walkways
• Building frames – Shell structure
• Trusses – Roof and floor truss chords
• Solar racking – Mounting structure members
• Shelving – Uprights, braces
• Stair stringers – Supports, handrails

C sections provide excellent strength-to-weight ratio for structural applications.

Benefits of C Frame Roll Forming

Key benefits of C frame roll forming lines:

• High productivity – Up to 35 meters per minute
• Material savings – Zero scrap from C-shaped structure
• Consistency – Dimensional accuracy better than other methods
• Flexible – Produce wide range of C sections
• Cost-effective – Lower investment than structural mill
• Compact – Small footprint, easy installation
• Safety – Fully enclosed guards for protection
• Sustainable – Major energy and carbon reduction

C sections produced on roll formers rival structural mills in quality and performance at a fraction of investment cost.

Leading Manufacturers of C Frame Roll Formers

Prominent global suppliers of C section C frame roll forming machines include:

• Cloudnine – Feature rich heavy-duty roll formers
• Zhongfu – Advanced German engineering standards
• Jupiter Roll Forming – Customized production lines
• RollMax – Precision C sections up to 550 mm
• Formtek – Servo-electric lines for speed and accuracy
• Gasparini – Robust Italian-made roll forming machines

Cost Analysis

Typical cost considerations for C frame roll forming lines:

• Type and size – Larger, automated lines cost more
• Speed and efficiency – Directly affects pricing
• Material thickness – Machines for thicker sheets cost extra
• Quick change features – Adds expense but saves time
• Additional tooling – Varies based on profiles needed
• Installation and training – Often included in price
• Freight and logistics – Extra depending on delivery location

Total Acquisition Cost – $80,000 to $500,000+

Higher production capability warrants bigger investment to maximize productivity gains.

Buying Considerations

Key factors to consider when buying C frame roll forming machines:

• Size and thickness range of C sections required
• Estimated production volume and annual output
• Level of automation features preferred
• Available installation space for the line
• Planned operating shifts per day
• Operator skill level and training needs
• Expected part dimensional precision
• Future tooling needs and line expansion
• Local technical support capability

Thoroughly analyzing present and future needs ensures ideal equipment selection.

Maintenance Tips

Recommended maintenance practices for C frame roll formers:

• Daily cleanup of metal debris and excess lubricant
• Checking oil levels in gearboxes and hydraulics
• Inspecting roll tooling condition and replacing worn items
• Verifying hydraulic seals, hoses, fittings are not leaking
• Confirming electrical wiring and connections are tight
• Monitoring belt tension and chains for stretch
• Testing emergency stop and safety circuits
• Documenting maintenance activities and part changes

Proper maintenance improves uptime, output consistency and operator safety.

Troubleshooting Common Problems

Troubleshooting tips for C frame roll forming issues:

Profile distortion

• Check roll alignment and spacing
• Replace any damaged or worn rolls
• Adjust roll pressure as needed

Cut sections out of alignment

• Check alignment of cutting blade
• Inspect sensor positioning

Uneven line speed

• Test servo motors and drives
• Check for slipping belts or chains

Hydraulic power loss

• Inspect cylinders, valves and pumps
• Check oil level and filter
• Tighten any leaking fittings

Machine jamming

• Increase lubrication
• Clear any debris in stations
• Verify no loose machine parts

FAQs

What sizes of C sections can be produced?

Common ranges are 100 to 300 mm height, 1.5 to 3 mm thickness, and 750 to 1250 mm width capacities. Larger sizes are also possible.

What materials can the C frame roll former process?

Most commonly galvanized steel, also pre-painted steel, stainless steel or aluminum. Mild steel is the most cost-effective choice.

What thickness of sheets can be formed?

Standard C frame roll formers accommodate 1.2 to 3 mm material thickness. Special models for thicker sheets are available.

What is the typical output speed?

25-35 meters per minute is standard for most C frame roll forming lines. Speeds vary based on part size and features.

What length of C sections can be produced?

Standard roll former cutting lengths range from 2 to 12 meters. Extended lengths can be achieved by adding additional rolling stations.

Conclusion

C section C frame roll forming lines deliver high precision structural steel profiles at productivity rates unmatched by other methods. When specifying C frame roll forming equipment, manufacturers must assess both current and future part needs in terms of sizes, thicknesses, volumes, and tooling flexibility. Investing in a roll former sized appropriately for production demand can yield rapid payback through material savings, reduced labor, and energy efficiency versus other fabrication approaches.

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