helen@hbxinnuorollforming.com
Makes corrugated wave sheets and IBR trapezoidal panels alternately
Two roller decks stacked vertically share common drive and cutting unit
Progressive forming stations gradually bend flat steel into finished profile
PLC digital screen programs sheet making length and production batch quantity
Hydraulic post shear cuts made sheet at programmed length during operation
Hard chrome roller coating protects galvanized steel surface from scratching
Decoiler making machine and runout table delivered as complete package
This double layer making machine produces two types of metal roofing sheets from a single compact production unit by housing two complete roller forming decks in one welded structural steel frame. The lower deck makes traditional corrugated wave sheets — the sinusoidal-profile metal roofing product that has been the world's most affordable and widely used building material for over a century, serving residential housing, agricultural sheds, and economy construction across every continent. The upper deck makes IBR (Inverted Box Rib) trapezoidal profile sheets — a deep-rib structural panel engineered for long-span industrial roofing, commercial building envelopes, and cyclone-resistant construction where superior strength and weather performance are required. By combining both making capabilities in one machine, manufacturers can produce the full spectrum of metal roofing products demanded by their local construction market without owning and maintaining two separate production lines.
| Making Phase | Station Reference | Steel Transformation Process |
|---|---|---|
| Strip Reception and Guiding | Station 1 | The flat steel strip arrives from the hydraulic decoiler under regulated brake tension. The first roller pair receives the strip and constrains it laterally, establishing the sheet centerline. Initial edge forming begins as the material enters the making sequence through the entry guide channel |
| Primary Profile Initiation | Stations 2–5 | Profile-specific roller contours begin bending the steel at the exact positions where corrugated wave crests or IBR ribs will develop. Each station applies a controlled 5–10 degrees of angular deformation. The steel remains safely within its forming limits at this stage, protecting the galvanized coating from stress-induced micro-cracking |
| Intermediate Shape Development | Stations 6–12 | Wave troughs deepen and crests sharpen for corrugated sheets; rib side walls steepen and valley floors flatten for IBR sheets. The steel undergoes progressive plastic flow across seven consecutive stations, achieving uniform deformation distribution that preserves consistent sheet gauge thickness in all bent profile zones |
| Final Profile Completion | Stations 13–16 | The last active forming rollers establish the finished sheet dimensions — wave amplitude and pitch for corrugated output; rib height, valley width, and side lap geometry for IBR output. Engineered springback compensation built into the roller geometry ensures the made sheet retains its design profile after exiting the forming zone |
| Calibration Pass | Stations 17–18 | A final sizing roller pair performs a quality verification pass, eliminating any residual dimensional variation. At this point the sheet has achieved its completely engineered cross-section, measured to within ±0.5mm of the profile drawing across the entire sheet width |
| Tooling Feature | Corrugated Sheet Making Deck | IBR Sheet Making Deck |
|---|---|---|
| Roller Station Quantity | 13–16 pairs of upper and lower making rollers | 14–18 pairs of upper and lower making rollers |
| Roller Raw Material | 45# medium carbon forged steel billet; ultrasonic inspected for internal flaw detection prior to machining | 45# medium carbon forged steel billet; ultrasonic inspected for internal flaw detection prior to machining |
| Profile Machining Method | CNC contour turning with sinusoidal wave form tooling; profile accuracy ±0.05mm | CNC contour turning with trapezoidal rib form tooling; profile accuracy ±0.05mm |
| Heat Treatment Process | Controlled-atmosphere gas carburizing; oil quench; surface hardness HRC 58–62 with impact-resistant ductile core | Controlled-atmosphere gas carburizing; oil quench; surface hardness HRC 58–62 with impact-resistant ductile core |
| Chrome Surface Plating | Industrial hard chrome electrodeposit; minimum 0.05mm thickness; mirror-polished finish eliminates sheet surface friction | Industrial hard chrome electrodeposit; minimum 0.05mm thickness; mirror-polished finish eliminates sheet surface friction |
| Drive Shaft Specification | Φ75–Φ80mm 40Cr alloy steel; precision ground to h7 tolerance grade; keyway slot for drive sprocket | Φ75–Φ80mm 40Cr alloy steel; precision ground to h7 tolerance grade; keyway slot for drive sprocket |
| Bearing Configuration | Split pillow block cast iron housing; double-row self-aligning spherical roller bearing; Zerk grease fitting lubrication | Split pillow block cast iron housing; double-row self-aligning spherical roller bearing; Zerk grease fitting lubrication |
| Made Product Parameter | Corrugated Sheet Output | IBR Sheet Output |
|---|---|---|
| Finished Sheet Cover Width | 660mm to 1000mm effective coverage | 762mm to 1100mm effective coverage |
| Profile Height/Depth | 12–18mm total wave crest-to-trough amplitude | 28–43mm rib crown elevation above valley base |
| Waves or Ribs per Sheet | 5, 7, 9, or 11 sinusoidal wave undulations | 4, 5, or 6 trapezoidal stiffening ribs |
| Sheet Length Making Range | 1.0m minimum up to 14.0m maximum per made sheet | 1.0m minimum up to 14.0m maximum per made sheet |
| Side Connection Method | 1.5-wave minimum side overlap for weather-tight longitudinal sheet joint | Single overlap with optional anti-capillary groove for water-sealed side lap |
| Flat Coil Input Required | 914–1220mm wide strip before making process | 1000–1250mm wide strip before making process |
| Machine Section | Engineering and Build Specification |
|---|---|
| Welded Structural Chassis | Heavy-gauge channel steel longitudinal members with cross-braced H-beam vertical support columns (300H–400H structural grade). The complete welded assembly receives post-fabrication thermal stress-relief treatment in an industrial annealing furnace to neutralize all residual weld stresses. After heat treatment, every bearing housing mounting surface is precision machined flat to guarantee absolute shaft parallelism across all roller stations in both making decks |
| Motor and Gearbox Drive | 5.5kW or 7.5kW AC induction motor (4-pole, 1440 rpm, IP54 enclosure protection) directly coupled to a worm-type dual-output shaft speed reducer with oil-bath gear lubrication. Available reduction ratios: 1:40 for higher-speed making of thin-gauge sheets or 1:59 for higher-torque making of thicker-gauge sheets. Each output shaft independently drives one complete making deck through a dedicated heavy-duty double-row industrial roller chain circuit with hardened alloy steel sprockets on every roller shaft and individual chain tension adjustment per loop |
| Hydraulic Cut-Off Assembly | 4.0kW gear-type hydraulic pump motor powering an 80-liter oil reservoir system with inline filtration, breather cap, sight glass oil level indicator, and oil temperature monitor. Flying shear carriage assembly rides on precision linear guide rails with pneumatic sheet clamp mechanism. The Cr12MoV cold-work die steel blade set is vacuum heat treated to HRC 60–64 and profile-ground to match the sheet cross-section for clean, burr-free cuts that do not distort the made sheet profile geometry |
| Digital PLC Control Architecture | Programmable logic controller (brand selection: Siemens S7-1200, Delta DVP series, or Mitsubishi FX3U per customer specification) with variable frequency drive inverter for stepless making speed regulation. Operator interface: 7-inch or 10-inch color LCD touchscreen HMI with multi-language display support and programmable recipe memory. Real-time sheet length measurement via rotary pulse encoder on the final forming shaft with digital feedback to the PLC auto-correction logic. Safety systems: mechanical limit switches at shear carriage home and over-travel positions plus three emergency stop mushroom-head pushbuttons located along the making line at the operator console, shear station, and discharge area |
| Pos. | Equipment | Role in the Sheet Making Operation |
|---|---|---|
| 1 | Hydraulic Mandrel Uncoiler | Holds the raw steel coil on hydraulically expanding jaws with 5-ton or 8-ton load capacity. Adjustable disc or pneumatic band brake maintains consistent strip pay-off tension for uniform sheet making quality from the first meter to the last meter of each coil |
| 2 | Entry Guide with Pre-Shear | Adjustable-width side alignment roller rails center the incoming strip on the making machine centerline axis. Integrated manual guillotine blade squares the coil leading edge before the strip is threaded into the chosen roller deck for production start-up |
| 3 | Double Layer Main Making Unit | Core production station combining the lower corrugated sheet making deck and upper IBR sheet making deck in one structural frame. A pivoting diverter plate at the machine entry directs the strip into the active deck. Both decks share a single drive motor, dual-output gearbox, chain drive loops, hydraulic shear, and PLC digital controller |
| 4 | Flying Hydraulic Post-Cut Station | Upon receiving the cut trigger signal from the PLC, the shear carriage accelerates to match the making line speed. A pneumatic clamp secures the formed sheet, the hydraulic cylinder drives the profiled blade through the sheet cross-section, then both blade and carriage retract to home position — the complete cut-and-return cycle is executed without pausing continuous sheet making production |
| 5 | Digital Control Enclosure | IP54 weatherproof steel cabinet containing the PLC central processor, VFD inverter, motor contactors, overload protection relays, circuit breakers, and terminal connection blocks. The color touchscreen HMI panel is externally mounted for operator access to sheet length programming, batch quantity setting, making speed adjustment, and fault diagnostic display |
| 6 | Discharge Roller Conveyor | 3m–5m free-roller receiving table with height-adjustable support legs. Catches finished cut sheets as they exit the shear station and provides a stable platform for manual stacking into product bundles for strapping, warehousing, and customer delivery |
| Specification Item | Technical Data |
|---|---|
| Compatible Coil Materials | Hot-dip galvanized steel (GI zinc coating Z60–Z275 g/m²), pre-painted galvanized iron (PPGI with polyester, SMP, or PVDF paint system), aluzinc/Galvalume (AZ150–AZ200), cold-rolled steel strip, aluminum alloy sheet grades 1100 and 3003 |
| Steel Gauge Making Range | 0.25mm to 0.80mm (approximately gauge 30 through gauge 20) |
| Material Yield Strength Limit | 200 MPa to 400 MPa covering standard mild steel through high-tensile structural steel grades |
| Production Making Speed | 10–18 linear meters per minute; infinitely variable speed adjustment through the VFD inverter digital control interface |
| Made Sheet Length Precision | ±1.0mm at any programmed sheet length via rotary encoder digital pulse feedback to the PLC auto-correction algorithm |
| Sheet Type Changeover | Manual pivoting material diverter plate repositioning; switch from corrugated sheet making to IBR sheet making in approximately 10–15 minutes including strip re-threading into the alternate deck |
| Electrical Power Input | 380V 50Hz 3-phase standard configuration; custom voltage (220V, 415V, 440V, 480V) and frequency (50Hz or 60Hz) configured to match the destination country power grid |
| Total Connected Motor Power | Approximately 10–12 kW (main drive motor 5.5/7.5kW + hydraulic pump motor 4.0kW combined) |
| Machine Overall Dimensions | Approximately L 7.0–8.0m × W 1.4–1.6m × H 1.7–2.0m; exact dimensions determined by ordered roller station count and frame specification grade |
| Machine Net Weight | 5.0 to 7.5 metric tons depending on the profile configuration, roller station quantity, and frame structural grade selected |
| Uncoiler Coil Rating | 5 metric tons standard duty or 8 metric tons heavy duty per customer daily production throughput requirement |
| Coil Bore Diameter | Φ508mm industry standard bore; Φ610mm with uncoiler mandrel adapter sleeve available on request |
| No. | Operation | Workflow Description |
|---|---|---|
| 1 | Coil Loading | Raw steel coil positioned onto the hydraulic uncoiler mandrel using an overhead crane or coil loading cart. Hydraulic expansion jaws engage and securely lock the coil inner bore. Brake resistance is set to the required drag level for uniform strip tension delivery throughout the making run |
| 2 | Strip Entry Preparation | The coil leading edge is threaded through the adjustable entry side guide roller assembly to achieve precise centerline alignment with the making machine axis. The manual pre-shear guillotine blade trims the coil head square before the strip enters the roller deck |
| 3 | Making Deck Selection | The operator positions the pivoting diverter guide plate: downward orientation feeds the strip into the lower corrugated sheet making deck; upward orientation feeds it into the upper IBR sheet making deck. Switching between the two sheet types requires approximately 10 minutes for diverter repositioning and strip re-threading |
| 4 | Progressive Sheet Making | The flat steel strip advances sequentially through the complete series of roller station pairs. At each station the metal undergoes controlled incremental bending deformation. By the final forming station the strip has been transformed into a fully formed corrugated wave sheet or complete IBR trapezoidal profile sheet ready for cutting to length |
| 5 | Length Measurement | A rotary pulse encoder coupled to the final drive shaft sends continuous digital pulses to the PLC processor. The controller compares the real-time accumulated pulse total against the operator-programmed target sheet length value displayed on the touchscreen HMI panel |
| 6 | Automated Sheet Cut | When the target length is reached the PLC triggers the automated cutting sequence: pneumatic clamp grips the formed sheet → shear carriage accelerates to synchronize with the making line speed → hydraulic cylinder drives the profiled Cr12MoV blade through the sheet cross-section → blade retracts and carriage returns to the home position — the entire cut cycle completes without stopping or slowing sheet production |
| 7 | Sheet Collection | The separated finished sheet slides onto the free-roller discharge conveyor table. The operator lifts each completed sheet and stacks it onto the product pallet or bundle for strapping, finished goods warehousing, and delivery to building material customers |
| Investment Category | Two Independent Single-Layer Making Machines | One Double Layer Making Machine |
|---|---|---|
| Equipment Purchase Cost | 100% — full price of two complete making machines plus two uncoilers | Approximately 65–75% of the two-machine combined total price |
| Workshop Floor Space | 44–70 square meters occupied by both making lines | 20–35 square meters for one dual-output making line |
| Ocean Container Freight | Two 20GP containers with two separate freight charges | One 20GP or 40HQ container with single consolidated freight invoice |
| Foundation and Utility Setup | Two concrete machine pads, two power supply drops, two cable installations | One concrete machine pad, one power supply drop, one cable installation |
| Production Workers per Shift | 3–4 operators needed across two separate making lines | 1–2 operators sufficient for one dual-deck making line |
| Monthly Electricity Consumption | Two drive motors and two hydraulic pump motors running continuously | One drive motor and one hydraulic pump motor — approximately 40% lower monthly energy cost |
| Spare Wearing Parts Inventory | Two complete sets of spare components in warehouse stock | One spare parts kit services both making roller decks |
Before export crating, each completed making machine is subjected to a thorough three-phase quality verification protocol. Phase one — comprehensive dimensional inspection: every roller gap at every forming station is measured with calibrated feeler gauges against the engineering tolerance specification; shaft runout is checked at all bearing positions using dial test indicators; frame alignment and squareness are confirmed with precision spirit levels and cross-laser measurement instruments. Phase two — extended no-load operational trial: the machine operates continuously at maximum rated making speed without material for a minimum of four hours; bearing housing temperatures are recorded at 30-minute intervals using infrared thermometers; chain drive engagement is assessed visually and audibly for smooth sprocket tooth meshing; every PLC function undergoes operational validation including power-up sequence, motor start-stop, making speed adjustment, sheet length value programming, batch quantity setting, recipe storage and recall, emergency stop circuit activation, and system restart — confirming complete and fault-free control system integration. Phase three — live making production trial: factory technicians load genuine galvanized steel coil stock and make 50 consecutive corrugated sheets plus 50 consecutive IBR sheets; every 10th made sheet is measured for length, wave pitch or rib geometry, and cut edge quality using calibrated digital measuring instruments. Only machines that achieve zero out-of-tolerance measurements across all three inspection phases receive approval for export packaging and container loading.
The main making machine body receives comprehensive multi-layer protective export packaging designed for ocean freight transit: an inner wrap of VCI (volatile corrosion inhibitor) anti-rust protective film; a middle layer of high-density closed-cell foam padding applied to all corners, machined surfaces, and protruding components; an outer wrap of heavy-gauge UV-stabilized polyethylene shrink film providing moisture, dust, and mechanical handling protection. The wrapped assembly is bolted through its base frame to a fumigated ISPM-15 certified plywood pallet or welded structural steel export skid. The hydraulic uncoiler, sheet discharge roller conveyor table, hydraulic power pack unit, and digital control enclosure are each packed individually in purpose-built marked fumigated wooden crates with internal foam bracing and bolted tie-downs for secure transit. A dedicated accessories crate contains the operator hand tool kit, starter set of spare wearing parts, and a complete printed technical documentation package: mechanical assembly drawings with exploded component identification views, electrical wiring schematic with terminal block and wire number labeling, PLC parameter programming and configuration reference guide, daily and weekly lubrication schedule chart with recommended grease specifications, and the comprehensive English-language operation and maintenance manual. Standard manufacturing lead time is 25–35 working days from confirmed deposit receipt and customer-signed profile approval engineering drawings. Standard warranty coverage is 12 months from the bill of lading date against defects in materials and factory workmanship.
| Optional Upgrade | Description and Production Benefit |
|---|---|
| Servo Motor Drive Conversion | Replace the standard AC induction motor with a programmable servo drive system for precision-controlled making acceleration and deceleration profiles, enhanced sheet length accuracy, and reduced electrical power consumption during intermittent production cycles |
| Automatic Sheet Stacking Mechanism | Motorized stacking arm assembly transfers finished made sheets from the discharge conveyor table to neatly aligned product bundles on a waiting pallet, eliminating manual sheet handling labor and reducing operator fatigue during extended production shifts |
| Electric Coil Loading Trolley | Battery-powered cart operating on floor-mounted guide rails with hydraulic scissor lift platform; safely transports raw steel coils weighing up to 10 tons from warehouse storage directly to the uncoiler mandrel without overhead crane dependence |
| IoT Remote Production Monitor | 4G cellular-connected module that transmits real-time making production metrics — daily sheet output tally, motor operating hours, fault diagnostic codes, and scheduled preventive maintenance interval reminders — to a dedicated smartphone application or web-based production management dashboard |
| Custom Embossing Roller Pair | Specially engraved forming roller pair integrated into the making sequence that permanently imprints a manufacturer brand name, company logo, or production batch code into each sheet during the making process for product identification and brand recognition |
| Stainless Steel Roller Tooling Option | Complete making roller set manufactured from grade 304 or 316L austenitic stainless steel for sheet making operations in food-grade processing facilities, pharmaceutical production plants, chemical industry manufacturing environments, or high-salinity coastal production locations where standard rollers would be vulnerable to corrosion attack |
Hebei Xinnuo is a professional cold roll forming machinery manufacturer with 20+ years of experience. We specialize in C/Z purlin machines, roof panel roll formers, floor deck machines, and custom profile solutions — exported to 50+ countries worldwide.
