C Section C Frame Roll Forming Machine

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.

c section c frame roll forming machine
C Section C Frame Roll Forming Machine 3

Specifications of C Frame Roll Formers

Typical specifications of C frame roll forming machines:

ParameterSpecification
Roller diameter100-180 mm
Max. line speed35 m/min
Min sheet thickness1.2 mm
Max sheet thickness3 mm
Sheet width750-1250 mm
C section height100-300 mm
Cut lengths2-12 meters
Main motor11-55 kW
Voltage380-415V, 50/60Hz, 3Phase

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
c section c frame roll forming machine
C Section C Frame Roll Forming Machine 4

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.

استنتاج

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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