Roll forming allows continuous, efficient and economical production of custom profiles from metal coils using roller dies. OEM light keel roll forming machines produce light keel sections rapidly to consistent specifications.
This guide explores key aspects of procuring and leveraging oem light keel roll formers for optimal productivity.
Overview of OEM Light Keel Roll Forming Machines
OEM stands for original equipment manufacturer. OEM light keel roll forming machines are customized to mass produce light keel profiles as per design needs.
Available in manual, semi-automatic and fully automatic variants, key advantages are:
- High production speed
- Consistent quality output
- Cost effective volume production
- Customization for profile requirements
- Quick changeovers between sizes
- Scalability for increasing demand
Additional enhancements like holes punching, notching, hole patterns etc. can also be integrated in line with profile requirements.
Types of OEM Light Keel Roll Formers
Table 1: Major Types of OEM Light Keel Roll Forming Machines
| Machine Type | Description |
|---|---|
| Manual | Basic model with manual material handling |
| Semi-Automatic | Automated forming but manual feed/cutoff/exit |
| Fully Automatic | Fully automated material flow and post-forming operations |
| Single Profile | Designed for one profile shape |
| Double Profile | Creates two profiles simultaneously |
| Fixed | Stationary design with fixed layout |
| Movable | Portable design with flexible layout |
| Light Duty | For thinner gauges and smaller widths |
| Heavy Duty | For thicker gauges and wider coils |
Working Principle of Roll Forming
Gradually bending metal strip through a series of stands containing roller dies to shape it into desired cross-section.
Key Stages:
- Uncoiling – Sheet coil loaded onto a decoiler
- Feeding – Strip fed into the roll former
- Pre-bending – Initial shaping
- Forming – Final shaping by roller dies
- Post-forming – Additional features if needed
- Cutting – Cut to length by built-in cutter
- Exit conveyor – Formed cut lengths exits machine
Material Handling Considerations
- Coils – Sheet metal in rolled continuous strips
- Decoiler – Feeds strip from uncoiling coils
- Accumulator – Allows continuous running
- Coil Joiner – Joins new coil to end of old one
- Straightener – Removes coil curvature
Profile Shaping Capabilities
Modern OEM light keel roll forming machines can produce:
- Plain “C” type light keels
- Insulated double skin foam filled
- Single skin lighter profiles
- Various special edge bending styles
- PVC coated variants
Forming Limits
- Metal thickness up to 3 mm
- Strip width up to 1250 mm
- Profile height up to 300 mm
Additional Features
- Punching – Holes for connections etc.
- Notching – Special cutouts if required
- Embossing – Brand name, logo imprinting
- Special cuts – Custom edge shapes
- Special bends – Scrolls, hems etc.
- Coatings – Powder coating, galvanizing
Key Specification Parameters
Table 2: Main Parameters for OEM Light Keel Roll Forming Machines
| Parameter | Typical Values |
|---|---|
| Speed | 10-100 m/min |
| Thickness | 0.3-3 mm |
| Strip Width | 50-1250 mm |
| Profile Height | 50-300 mm |
| Roller Size | >100 mm diameter |
| Number of Stands | 8-24 |
| Motor Power | 5.5-132 kW |
| Voltage | 220-480 V, 50/60 Hz, 3 phase |
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How to Select an OEM Light Keel Roll Former Machine Manufacturer
Key factors in selecting OEM light keel roll forming partner:
Table 3: OEM Light Keel Roll Former Machine Manufacturer Selection Criteria
| Consideration | Details |
|---|---|
| Experience | Years in business, clientele served |
| Design Expertise | Custom profile engineering |
| Manufacturing Facility | Usage of advanced machinery |
| Product Range | Portfolio coverage |
| Quality | Standards compliance guarantee |
| Commissioning Support | Installation help, training |
| After-sales Service | Maintenance contracts, spares supply |
| Delivery Time | Production and shipment schedule |
| Pricing | Reasonable transparent quotes |
| Global Presence | Sales and service support coverage |
As technology evolves, partnering with roll forming specialists like [company name] ensures leveraging latest process expertise for light keel profile manufacturing.
Price Range of OEM Light Keel Roll Forming Machines
Pricing varies based on:
- Level of automation
- Production speed rating
- Drive system motor and gearing
- Machine size and coil width capacity
- Material thickness handling
- Additional integrated features
- Quality and precision norms followed
- Manufacturer’s reputation and volumes
Table 4: Indicative Pricing for OEM Light Keel Roll Forming Machines
| Production Speed | Price Range |
|---|---|
| Low (<20 m/min) | $16,000 – $70,000 |
| Medium (20-50 m/min) | $52,000 – $160,000 |
| High (>50 m/min) | $85,000 – $240,000 |
Leading OEM suppliers offer significant value advantage stemming from process expertise and manufacturing volumes while delivering high precision equipment.
Installing an OEM Light Keel Roll Former
Correct installation ensures smooth functioning. Checklist covers:
Table 5: OEM Light Keel Roll Forming Machine Installation Guidelines
| Activity | Instructions |
|---|---|
| Site Readiness | Level floor, power supply, lighting |
| Unpacking | Careful removal without damage |
| Positioning | Ensure proper clearances |
| Levelling | Use spirit level for perfect horizontal |
| Anchoring | Tighten anchor bolts to avoid vibrations |
| Electrical Connections | Link to suitable power source |
| Pneumatic Connections | Connect compressed air if required |
| Trial Runs | Test functions as per operating manual |
| Commissioning | Production testing and final checks |
Seeking machine supplier’s specialists’ guidance during installation avoids issues later.
How to Operate an OEM Light Keel Roll Former
Efficient operation maximizes productivity and roll formed product quality:
Table 6: OEM Light Keel Roll Forming Machine Operating Guidelines
| Activity | Procedure |
|---|---|
| Safety | Wear protective accessories, enable safeguards |
| Material Loading | Use appropriate handling equipment |
| Machine Settings | Set speed, thickness, width parameters |
| Startup | Follow sequence given in manual |
| Running | Monitor strip flow, sensors, lubrication etc |
| First Piece Check | Verify dimensions and finish |
| Shutdown | Follow shutdown sequence in manual |
| Data Recording | Note production counts, observations etc |
Proper training to operators on ideal machine handling, troubleshooting and maintenance procedures is vital.
Maintenance Guidelines for OEM Light Keel Roll Formers
Scheduled maintenance activities are crucial for consistent high performance:
Table 7: OEM Light Keel Roll Forming Machine Maintenance Schedule
| Frequency | Tasks |
|---|---|
| Daily | Clean dust/dirt, lubricate points, verify settings |
| Weekly | Inspect electricals, pneumatics, safety devices |
| Monthly | Check roller wear, drive transmission condition |
| Quarterly | Lubricant change, hoses & pipes check, production audit |
| Yearly | Complete overhaul, replace worn components |
Additional best practices:
- Maintain updated records of all machine parameters
- Analyze parameter trends to prevent sudden failures
- Plan replacement of wear components
Proactive maintenance enhances machine availability and lowers costs.
Advantages and Limitations of OEM Light Keel Roll Formers
Table 8: Pros and Cons of OEM Light Keel Roll Forming Machines
| Advantages | Limitations |
|---|---|
| Excellent part consistency and accuracy | Higher initial purchase cost |
| High production speed with automation | Require significant setup area |
| Low operating costs thanks to electric drives | Size limits in a given model |
| Minimal supervision needed | Roll design expertise needed |
| Safer than press brakes or shears | Not ideal for very low quantities |
| Wide range of profiles can be shaped |
For current and future production volumes, OEM light keel roll forming lines provide efficient fabrication solutions.
FAQ
Q: What sheet metal materials can you use?
A: Most thin, ductile metal coils like low carbon steel, stainless steel, aluminium etc. under 3 mm thickness.
Q: What profile dimensions are possible?
A: Around 300 mm maximum profile height and 1250 mm max strip widths are possible in standard models. Custom built variants can go bigger.
Q: How easy is it to switch between profiles?
A: Manual machines allow profile changeovers in 1-2 hours. For automatic lines, expect around 4-6 hours since mechanical & controls adjustments are required.
Q: What support do OEM suppliers provide?
A: Reputed manufacturers offer complete support for machine shipping, installation, operator training as well as prompt after-sales service.
Q: What are typical warranty terms?
A: Most OEM suppliers offer 12-18 month standard warranties on light keel roll forming machines covering materials and workmanship defects.
