Engel Roll Forming Machines

November 2, 2023

Overview of Engel Roll Forming Machines

Engel roll forming machines are high quality roll forming systems used to produce metal roofing, panels, decking, solar module frames, and various structural profiles. Key features:

Offered by Engel Machinery Inc., a major roll forming equipment supplier.
Continuous production of profiles from coiled sheet metal.
Capable of complex profiles with ribs, curves, embossing and other features.
Quick changeover of roll tooling for flexible production.
Range of automation options available for material handling, cutoff, and part stacking.
Touchscreen HMI controls with recipe storage for easy changeovers.
Used by manufacturers to produce cladding, panels, roofing for building industry.
Servo roll adjustment and passive roll technology for quality parts.

Typical Products Made on Engel Roll Formers

Metal roofing – standing seam, horizontal, tile, shake
Wall panels, siding, liners
Structural studs, girts, joists, tracks
Floor and roof decking
Solar module frames
Special architectural profiles

Engel machines produce a wide range of standard and custom building components.

Key Specifications

Parameter	Capabilities
Forming width	18 – 80 inch range
Material thickness	26 ga – 3/16 inch
Forming speed	Up to 400 ft/min
Pass schedule	Up to 20 forming stands
Controls	Touchscreen HMI, servo roll adjust
Tooling	Quick change cartridges, driven stands
Safety	Guarding packages, light curtains

Engel offers many standard models plus custom engineered solutions.

engel roll forming machine — Engel Roll Forming Machines 3

How to Select an Engel Roll Former

Key factors when selecting an Engel roll forming system:

Production requirements – Desired hourly output rate, coil widths/gauges, complexity of profiles to be produced.
Automation needs – Determine if manual or powered material handling, part cutoff, and stackers are required.
Tooling – Evaluate availability of standard tooling packages for desired profiles from Engel.
Controls – Determine necessary functionality like recipe storage, data logging, etc.
Technical support – Engel provides installation support, training, and service. Ensure regional availability.
Customization – Engel can provide customized features, safety add-ons, and instrumentation.
Expandability – Select a system that can have capacity increased in the future with capability to add additional passes.

Work with Engel application engineers early when specifying equipment to get a system tailored to your production requirements.

Roll Tooling Design Principles

Proper roll tooling design is key to producing quality roll formed parts efficiently on an Engel machine. Design guidelines:

Optimize part profiles for material flow and stiffening ribs, seams, and embossments to add rigidity.
Engineer roll contours to guide material through forming without thinning, tearing or cracking.
Design forming passes and roll penetration carefully to control stresses induced in material.
Match roll diameters top-to-bottom to ensure even bending and precise tolerances.
Lubricate rolls to reduce friction – use materials like urethane that support metal flow for hard alloys.
Reduce sharp bend angles which concentrate stress by using larger radii bends.
Annotate tooling drawings thoroughly with pass sequences and references to aid setup and changeovers.

Work jointly with Engel tooling engineers to arrive at optimal roll designs and sequences for robust production.

Preparing for Engel Roll Former Installation

To prepare for arrival and installation of a new Engel roll forming system:

Arrange for electrical supply required – confirm voltage, capacity. Install disconnects.
Provide adequate space with clearances for safe operation around machine. Allow for part conveyors.
Obtain any necessary permits – building, electrical, local codes.
Prepare rigid foundations according to Engel specifications to handle loads.
Have lifting equipment available – cranes, forklifts, chains etc. to offload components from trucks.
Schedule qualified technicians for installation, alignment, wiring, and debugging.
Order initial tooling packages and material coil stock to have on hand.

Thorough planning minimizes delays and issues when the equipment arrives onsite.

Installation Best Practices

Recommended practices when installing Engel roll formers:

Carefully offload components from trucks using appropriate lifting devices. Avoid damage.
Follow Engel documentation for proper assembly sequence and alignments.
Have electricians install power connections and control wiring per electrical prints.
Anchor machine securely to flooring – forming induces dynamic loads.
Install all safety guarding before powering up machine. Eliminate pinch points.
Validate proper jog direction on drives prior to running. Reverse as needed.
Gradually power up and cycle machine to confirm correct operation.
Make roll adjustments from infeed to exit end to debug tooling pass by pass.
Only release for production after successful commissioning trials prove out line.

Careful installation by qualified personnel helps avoid issues and ensures a smooth startup.

Roll Former Operation and Quality Control

To safely operate an Engel roll former at optimal quality:

Monitor line speed, web alignment, roll loads, and other variables continuously. Make adjustments as needed.
Frequently check formed part dimensions using go/no-go gauges. Ensure within tolerance.
Ensure input coil parameters match Engel recommendations – thickness, width, tensioning, lubrication etc.
Promptly replace any worn roll segments before scratches form on parts.
Schedule downtime for preventative maintenance during planned production stops.
Implement programmed safety stops and light curtains that halt operation when a fault occurs.
Control lubrication levels and top up reservoirs as needed to support continuous high speed operation.
Ensure operators are properly trained on all procedures and safety precautions.

Consistent quality output requires continuous monitoring, training, and disciplined operation within proven parameters.

Common Roll Forming Defects and Corrections

Defect	Possible Causes	Corrections
Burrs	Roll damage, web misalignment	Dress or replace rolls, realign guides
Wavy sections	Improper roll adjustment	Re-pen roll passes incrementally
Twisting	Non-parallel top/bottom rolls	Realign bottom roll parallel to others
Thinning	Excessive roll penetration	Loosen roll penetrations, shim gaps
Loose curl	Inconsistent roll adjustment	Gradual re-adjustment of problem passes
Scratches	Grit on rolls, web contamination	Clean rolls, improve input material surface

Observe part features closely and make systematic adjustments until defects are eliminated.

Roll Former Safety Considerations

Important safety practices when operating Engel roll formers:

Comprehensive operator training on hazards and proper procedures.
Adequate guarding around all pinch points, gears, coils. Avoid exposed hazards.
Lockout/tagout for maintenance activities and clearing jams. De-energize machine.
Enforce PPE requirements including snug clothes, gloves, glasses, and hearing protection.
Clearly mark out safety zones around machine. Follow any access rules.
Implement automatic safety stops for unsafe conditions like line jams.
Dust collection if needed to improve air quality in forming area.
Regular safety inspections to proactively identify risks – document corrective actions.

Prioritizing safety improves work conditions and prevents injuries. Follow all regulatory requirements.