Станок для формовки рулонных листов

А Листогибочная машина для формовки стеновых листов is an essential equipment for producing wall panels, roof panels, C & Z purlins and other structural building components from metal coils. This guide provides a comprehensive overview of wall sheet roll forming technology, types of machines, key specifications, applications, installation and maintenance requirements, supplier selection factors, comparative analysis and FAQs.

Overview of Wall Sheet Roll Forming

Roll forming is a continuous bending operation that forms metal coils into customized longitudinal profiles through a series of sequential rolling stands. Wall sheet roll formers transform flat metal sheets into finished wall, roof and structural framing products for buildings.

Core Advantages of Roll Formed Wall Sheets

  • Highly customizable profiles
  • Superior structural strength
  • Lightweight compared to other wall materials
  • Quick and efficient production
  • Consistent quality and dimensional accuracy
  • Cost-effective for mass production
  • Minimal waste generation

Types of Profiles Produced

Wall sheet roll forming machines can produce various standard and custom profiles as per application requirements:

Таблица 1: Common Roll Formed Wall Sheet Profiles

Profile TypeОписание
Trapezoidal roof & wall sheetsWavy corrugated profile, popular for cladding
Sinusoidal roof & wall sheetsSmooth curved corrugations for aesthetic finish
Standing seam roof sheetsInterlocking panels with raised seams
Ribbed wall sheetsNarrow raised longitudinal ribs for strength
Structural C & Z purlinsWeight-bearing frame components
Architectural wall panelsDecorative fluted, curved, textured sheets
Perforated wall sheetsHoles for ventilation and sound absorption

Key Components of a Wall Sheet Roll Former

The main sections of a typical wall profile roll forming machine include:

Таблица 2: Components of a Wall Sheet Roll Forming Machine

РазматывательHolds and rotates the metal coil
РазматывательStraightens the strip from the coil
ПитательFeeds the strip at a set speed
Punching UnitPunches holes if required for fastening
Станции формовкиProgressive bending and profiling stands
Cutting unitCuts sheets to specified length
ШтабелерCollects formed sheets automatically
PLC controlControls machine parameters and interlocks
Листогибочная машина для формовки стеновых листов
Wall Sheet Roll Forming Machine 3

Specifications of Wall Sheet Roll Formers

Key technical parameters and dimensional factors determine the production capacity, profile capabilities and performance of wall sheet roll forming machines.

Production Capacity Factors

Таблица 3: Technical Factors Affecting Production Capacity

ПараметрТиповой диапазон
Скорость формования10 - 25 м/мин
Working width1000 – 2500 mm
Sheet thickness0,3 - 2,0 мм
Main drive power5.5 – 15 kW
Cutting length500 – 6000 mm
Material yield strength250 – 550 MPa

Higher production speeds, wider coil widths, thinner gauges and lower yield strength materials allow faster forming and increased output.

Profile Dimensional Factors

Таблица 4: Technical Limits for Profile Shapes

DimensionТиповой диапазон
Глубина профиля10 – 150 mm
Wave height15 – 115 mm
Ширина фланца45 – 300 mm
Rib width10 – 45 mm
Bend radius2 – 8 mm
Punching diameter10 – 20 mm

Deeper and more complex shapes may require heavier machines and multi-pass processes.

Design and Construction Parameters

Таблица 5: Standard Machine Design Features

Станции формовки10 – 20 stands for sequential bending
Roller typesVertical, horizontal, oblique, edge rollers
Roller materialAlloy steel or hard chrome plated
Диаметр ролика100 – 160 mm
Регулировка роликовKeyed shafts, screw down, auto actuators
РамкаAll-welded steel construction
Strip guidanceRoller guides, strip edge shielding
БезопасностьEmergency stops, overload protection
Размер машиныLength 15 – 40 m; Height 2 – 2.5 m
Noise level≤80 db with acoustic covers

Applications of Wall Sheet Roll Forming Machines

Wall sheet roll forming machines produce panels and profiles from steel, aluminum and other metals for the following structural applications:

Таблица 6: End Use Applications of Roll Formed Wall Sheets

Wall claddingTrapezoidal, ribbed and corrugated sheets for exterior walls
КровляStanding seam, corrugated roof panels
Interior wallsDecorative roll formed sheets for partitions
Structural framingPurlins, girts, eaves for buildings
Сельскохозяйственные зданияLow cost roofing and walls for farms
Prefabricated buildingsFaster construction with premade panels
Container constructionAssembling homes, offices from roll formed sheets
Solar structuresStructural profiles for PV panel mounts
Acoustic barriersSound dampening perforated sheets

Key advantages of roll formed panels in these applications include lightweight, high strength, quick installation, design flexibility, corrosion resistance and longevity.

Установка и эксплуатация

Proper installation and operation practices are vital for optimum performance of wall sheet roll forming lines.

Руководство по установке

  • Foundations should be concrete or sturdy steel structures
  • Leveling and alignment of forming stands is critical
  • Roller adjustment should be precise with uniform gaps
  • Test run to verify profiles before production
  • Safety barriers, guards and fences should be in place

Эксплуатация и обслуживание

Таблица 7: Operation and Maintenance Requirements

Inspect formed profilesEach sheet or shift
Check roller adjustmentЕженедельник
Verify strip guidanceЕжедневно
Смазка подшипниковЕжемесячно
Inspect chains, gears, sprocketsQuarterly or 5000 hours
Replace worn rollersAfter 100,000 cycles or as needed
Calibrate sensors, actuatorsПо мере необходимости
Обновление программного обеспечения машиныAs needed for upgrades

Regular preventive maintenance improves product quality and avoids unplanned downtime.

Supplier Selection Considerations

Choosing the right roll forming machine supplier is key to getting capable and reliable equipment for wall sheet production.

Таблица 8: Key Criteria for Evaluating Roll Former Suppliers

Техническая экспертизаВысокая
Customization capabilitiesВысокая
Build quality and precisionВысокая
Line integration experienceСредний
Local presence and supportСредний
Производственная мощностьНизкий
International experienceНизкий
Cost competitivenessСредний

In addition to technical parameters, factors like responsiveness, transparency, lead time, payment terms, warranties and after-sales service should be evaluated during supplier selection.

Comparative Analysis

Тип машиныПреимуществаОграничения
МеханическаяSimple and robust
Easy maintenance
Proven reliability
Limited forming capacity
Lower precision
Slower speed
Servo motorHigh speed and accuracy
Быстрая переналадка
Advanced automation
Higher cost
Complex programming
Sensitive sensors
ГидравлическийPowerful forming force
Deep drawing ability
Oil maintenance
Slower than servos
Environment risks

Cost Analysis

Таблица 9: Price Range of Wall Sheet Roll Forming Machines

ЕмкостьДиапазон цен
Small (up to 30,000 tons/year)$50,000 – $150,000
Medium (up to 100,000 tons/year)$150,000 – $350,000
Large (above 100,000 tons/year)$350,000 – $1,000,000

Cost depends on speed, width, material thickness range, profile complexity, automation level and customization requirements. Local support and transportation costs also affect pricing.

Листогибочная машина для формовки стеновых листов
Wall Sheet Roll Forming Machine 4

Часто задаваемые вопросы

What materials can be roll formed into wall sheets?

  • Cold rolled steel, galvanized steel, stainless steel, aluminium sheets up to 2 mm thickness. Not recommended for thicker plates above 3 mm.

What should be the flatness and surface finish of the coil?

  • Coil flatness tolerance up to 3 mm per meter width is acceptable. Surface defects may mark the finished profiles.

What are the power requirements?

  • Wall sheet roll formers typically need 15 – 30 kW installed power depending on speed and capacity. Three phase 415 V AC supply is preferred.

How to adjust the roll forming stands?

  • Stands are adjusted by laser alignment or numerically controlled actuators. Keyed shafts, screwn down and shims allow manual adjustment along with Gauging stations.

Какие меры безопасности необходимы?

  • Emergency stop buttons, overload protection, strip containment guides, safety fences and light curtains to stop on obstruction. Acoustic covers reduce noise.

What digital controls are included?

  • PLC or HMI touchscreen controls for production monitoring, parameters adjustment and automated sequencing of machine. Servo systems allow precision control.

What is the normal maintenance routine?

  • Daily cleaning, weekly lubrication and inspection, monthly sensor calibration and quarterly gearbox oil change are typical maintenance tasks. Rollers require replacement based on wear.

In summary, wall sheet roll forming machines offer efficient, customized production of metal wall panels and framing components for buildings. This guide has provided a holistic overview of the technology, process, specifications, applications, operation, supplier selection and costs to inform purchase and use of this versatile equipment.

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