Double layer integrated roll forming machine is a fully automatic double-layer CNC cold roll forming machine set, specifically designed for modern metal cladding systems. Its core highlight is the perfect integration of two commonly used specifications: Type 840 and Type 900.
Specifications
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Item |
Content |
Remarks |
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Material |
Galvanized Color Steel Plate |
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Width |
1000 mm |
Special sizes are available upon request |
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Thickness |
0.25 mm - 0.6 mm |
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|
Color Matching |
Green Vertical Texture |
Customizable according to customer requirements |
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Overall Dimension (Approx.) |
6000 mm × 1300 mm × 1400 mm |
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|
Forming Rows |
11+9 rows |
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|
Forming Rollers |
45# Steel Finished, Hard Chrome Plated and Polished |
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Forming Roller Shaft |
Diameter 70 mm, 45# Steel Finished |
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|
Side Wall Plates |
16 mm |
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Frame Specification |
300H Steel |
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Motor Power |
3 KW Hydraulic Transmission |
Voltage can be customized to 380/220/240 |
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Transmission Mode |
Chain |
1 inch |
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Forming Speed |
8-12 m/min |
|
|
Shearing Mode |
Cut after Hydraulic Forming, Hydraulic Guided Shearing |
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Cutter Material |
Cr12 Heat-Treated |
Thickened, High Wear-Resistant Blade |
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Electric Control System |
Equipped with PLC, Touch Screen and Coding Counter |
Fully Automatic Batch Setting |
Product Features
Dual-Functionality, Cost-Effective
This single machine integrates two specifications. Compared to purchasing two separate machines, equipment procurement costs are reduced by approximately 30–40%, and the factory floor space required is cut by about 40%. Transportation and installation costs are also lowered, making it ideal for clients with limited factory space or those requiring frequent relocation between job sites.
Durable Rollers, High Forming Precision
The rollers are forged from 45# steel, quenched, and hard-chrome plated, achieving a surface hardness of HRC 55–58; they are highly wear-resistant and rust-proof. During the forming process, the sheet surface remains free of scratches and wrinkles, and the profile is crisp, ensuring the finished tiles offer excellent waterproofing and a neat, attractive appearance.
One-Touch Switching, Easy Operation
Switching between the upper and lower layers is easily done via a selector switch on the electrical control cabinet. Power is controlled separately by clutches, allowing for a switchover time of just 2–3 seconds. No mold changes or re-threading are required, and the machine can be operated by a single person, reducing labor dependency.
Independent Operation, Flexible Production
The double layer integrated roll forming machine features independent power and control systems for the upper and lower layers, allowing them to run simultaneously or individually. Maintenance on one layer does not halt production on the other, ensuring delivery schedules remain on track. Operating only one layer during low-volume periods saves electricity.
Applications
Roofing and wall cladding for industrial buildings such as steel structure factories, warehouses, vehicle garages, and aircraft hangars.
Roofing and wall systems for public buildings such as stadiums, exhibition centers, theaters, and large conference centers.
Roofing and wall systems for commercial buildings such as large supermarkets, logistics distribution centers, and wholesale markets.
Suitable for projects with limited site space where accommodating multiple machines is impractical; a single machine meets production needs for two common specifications.
Quality Control
Raw Material Inspection
Incoming steel and purchased components undergo batch sampling (at a rate of no less than 10%). Material certificates are verified against actual specifications, and non-compliant batches are returned in full.
Processing Control
Each roller undergoes individual hardness testing, with a report issued for each; main shafts undergo heat treatment (quenching and tempering) followed by concentricity and dimensional accuracy checks.
Assembly Inspection
Roller concentricity (≤0.05mm) and frame parallelism (≤0.10mm/m) are checked for each forming station; drive chains, bearing clearances, and other components are verified individually against standards.
Trial Production
A continuous trial run of at least 30 meters with material is conducted to inspect the profile forming quality and cutting precision (length tolerance within ±2mm); a video of the trial run is recorded and archived.
Electrical System Testing
Each PLC input and output point is tested via simulation to verify program logic, emergency stop functions, safety interlocks, and fault alarm systems.
Factory Record Management
A comprehensive quality dossier is created for each machine-including inspection records, hardness reports, trial run videos, and test reports-to facilitate future traceability.
FAQ
Q: Is it troublesome to switch between the 840 and 900 profiles? Do I need to change the rollers?
A: Switching is very convenient and requires no roller changes. The machine uses an independent double-layer roller shaft design. Simply select the corresponding profile on the PLC touch screen, and the machine will automatically adjust the material feed path. Profile switching can be completed within 3-5 minutes, truly achieving two machines in one.
Q: My workers are not highly educated. Is Double layer integrated roll forming machine complicated to operate?
A: The operation is very simple. The machine features an intelligent PLC and a touch screen. Workers only need simple training to input the sheet length and required quantity on the screen and press start. The machine then automatically completes the entire process from feeding to cutting, greatly reducing reliance on experienced operators.
Q: What do the "840" and "900" models represent, and what is the difference between them?
A: The numbers 840 and 900 refer to the effective coverage width of the formed panel (in millimeters). The 840 model has an effective width of 840mm and is typically used for roofing, offering smooth drainage and structural stability. The 900 model has an effective width of 900mm and is usually used for wall cladding, providing seamless joints and easy installation. Each specification has its own advantages; a single machine can handle both, allowing you to choose based on your needs.
Q: Can both layers operate simultaneously?
A: Yes, they can run simultaneously, or you can operate just one layer. The upper and lower layers feature independent drive and control systems, so they do not interfere with each other. For large orders, both layers can run at once; if only one specification is required, you can operate just the corresponding layer while the other remains idle, consuming no power.
Q: How much cheaper is the Double Layer Integrated Roll Forming Machine compared to two separate single-layer machines?
A: A double-layer machine costs approximately 30%–40% less than purchasing two separate single-layer machines, depending on the specific configuration. When factoring in savings on factory floor space, foundation construction costs, and shipping fees, the difference in total investment becomes even more significant.
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