helen@hbxinnuorollforming.com
Two profiles from one frame IBR and corrugated iron sheet roll former
Space-efficient vertical dual-deck design reduces workshop footprint by half
Heavy structural steel welded frame with stress-relief heat treatment
CNC-machined hardened rollers with anti-corrosion chrome surface coating
Intelligent PLC batch counter with automatic length presetting and fault alarm
Hydraulic cold shear produces clean cut edges without profile distortion
Suitable for galvanized iron zinc-coated and aluzinc raw coil material
This heavy industrial roll forming machine integrates two complete profile-making systems into one rigid vertical frame structure, enabling a single production line to manufacture both IBR (Inverted Box Rib) trapezoidal steel roofing sheets and traditional corrugated iron panels. Designed for manufacturers who supply galvanized iron roofing to construction markets, this machine eliminates the floor space and capital expense of running two independent roll formers. The upper roller assembly forms the IBR profile while the lower assembly handles corrugated iron wave geometry — switchover between the two simply requires repositioning the material feed guide, a task completed within minutes.
The load-bearing backbone is a fully welded structural steel frame fabricated from high-tensile H-beam or heavy channel steel sections (350H to 400H grade), thermally annealed post-welding to neutralize internal stress. Two independent roller trains are vertically stacked within this single chassis: the upper deck contains 14 to 18 forming stations configured for IBR rib geometry, while the lower deck holds 13 to 16 stations profiled for sinusoidal corrugated iron wave patterns. A common heavy-duty chain drive system transmits power from a single AC motor through a reduction gearbox, with synchronized sprockets ensuring identical linear feed speed through both roller sets.
Each forming roller begins as a 45# medium-carbon steel billet, CNC-turned to the exact profile contour, then undergoes case hardening followed by industrial hard chrome electroplating to a minimum deposit thickness of 0.05 mm. This dual treatment delivers a surface hardness of HRC 58–62, which is essential for two reasons: first, it prevents abrasive wear when processing zinc-coated galvanized iron coils where zinc oxide can accumulate on roller surfaces; second, the mirror-grade chrome finish eliminates micro-scratches on the sheet surface, preserving the galvanized coating integrity throughout the forming process. Each roller pair is mounted on Φ70–Φ80mm solid alloy shafts with precision keyways, supported by heavy-duty double-row self-aligning bearings in cast iron pillow blocks.
| Cutting Parameter | Specification |
|---|---|
| Shear Type | Flying hydraulic post-cut, synchronized with forming speed |
| Blade Material | Cr12 cold-work die steel, vacuum heat-treated to HRC 60–64 |
| Hydraulic Station | 4.0 kW / 5.5 kW motor-driven pump, working pressure 16–21 MPa |
| Length Accuracy | ±1.0 mm (PLC encoder feedback with auto-compensation) |
| Cut Edge Quality | Burr-free, no profile collapse at cut point |
| Blade Service Life | Approx. 500,000 cuts before re-sharpening |
| Dimension | Data |
|---|---|
| Profile Type | IBR (Inverted Box Rib) trapezoidal rib roof panel |
| Cover Width | 762 / 840 / 925 / 1050 / 1100 mm |
| Rib Pitch (center-to-center) | 200–250 mm depending on width variant |
| Rib Crest Height | 28–43 mm above valley plane |
| Side Lap Type | Overlap with anti-capillary groove (optional) |
| Dimension | Data |
|---|---|
| Profile Type | Traditional sinusoidal corrugated iron wave sheet |
| Cover Width | 660 / 750 / 800 / 900 / 1000 mm (after corrugation) |
| Wave Depth | 12–18 mm (crest to trough) |
| Wave Count | 5–11 waves depending on width specification |
| Pitch per Wave | 76.2 mm (3 inches) standard; custom pitches available |
| Item | Technical Detail |
|---|---|
| Raw Material | Galvanized iron coil (GI), zinc-coated steel, aluzinc (AZ), Galvalume, cold-rolled steel strip |
| Coil Thickness | 0.25–0.70 mm (thin-gauge corrugated iron); 0.30–0.80 mm (IBR) |
| Coil Yield Strength | 235–550 MPa (mild steel to high-tensile structural grade) |
| Coil Width (feed) | 1000–1250 mm before forming |
| Forming Speed | 10–18 m/min (infinitely adjustable via VFD inverter) |
| Main Motor Power | 5.5 kW / 7.5 kW AC induction motor with gearbox reducer |
| Hydraulic Power | 4.0 kW pump station with oil cooler and filtration unit |
| Roller Stations Per Deck | IBR: 14–18 rows; Corrugated: 13–16 rows |
| Shaft Diameter | Φ70–80 mm (standard); Φ85 mm (heavy-duty configuration) |
| Control System | PLC with 7-inch/10-inch color touchscreen HMI, multi-language UI |
| Cutting Mode | Flying hydraulic post-shear, cuts at full line speed without stopping |
| Voltage | 380V 50Hz 3-Phase (custom: 220V/415V/440V/480V 60Hz available) |
| Profile Switch Duration | 8–15 minutes (manual feed guide repositioning) |
| Overall Dimensions | L 7.0–8.0 m × W 1.4–1.6 m × H 1.7–2.0 m |
| Machine Net Weight | 5.0–7.5 metric tons (profile-dependent) |
| Step | Station | Operation Description |
|---|---|---|
| 1 | Decoiling | Galvanized iron coil mounted on hydraulic mandrel decoiler; active pay-off with loop control sensor regulates strip tension to prevent slack or over-tension |
| 2 | Feed Alignment | Side guide rollers center the strip; manual pre-shear trims coil head square before threading |
| 3 | Layer Selection | Operator routes strip into upper (IBR) or lower (corrugated iron) forming path via pivoting guide plate |
| 4 | Progressive Forming | Strip passes through sequential roller stations; each station applies incremental bend until final profile geometry is achieved at the last forming pair |
| 5 | Length Encoding | Rotary encoder mounted on final shaft measures linear travel; PLC triggers cut when preset length is reached |
| 6 | Hydraulic Shearing | Flying shear carriage moves synchronously with the sheet; hydraulic ram activates Cr12 blade for clean cut without line stoppage |
| 7 | Sheet Discharge | Cut sheet conveyed onto run-out table with support rollers; operator collects for stacking and bundling |
| Cost Factor | 2 × Single-Layer Machines | 1 × Double Layer Machine | Savings |
|---|---|---|---|
| Machine Cost | 100% (baseline) | 65–75% of baseline | 25–35% |
| Shipping Freight | 2 × 20GP containers | 1 × 20GP or 1 × 40HQ | 40–50% |
| Civil Foundation Work | 2 separate concrete pads + anchor bolts | 1 foundation block | ~50% |
| Electrical Installation | 2 power drops, 2 control panels | 1 power drop, 1 control panel | ~50% |
| Daily Operator Count | 3–4 workers | 1–2 workers | 40–50% labour |
| Spare Parts Inventory | 2 complete sets | 1 set (shared drive train) | ~50% |
Machine delivery includes a comprehensive English-language technical dossier: mechanical assembly drawings with exploded views, electrical wiring schematics, PLC parameter configuration table, lubrication schedule chart, and a troubleshooting flowchart covering 40+ common operational issues. On-site commissioning by a factory-trained engineer is available as an optional service, covering machine leveling and anchoring, roller gap calibration for both decks, PLC parameter setup and trial production of minimum 50 sheets per profile, plus hands-on operator training. Post-installation, customers receive 12 months of complimentary remote technical support via video call, with spare wearing parts (one spare shear blade, 5 meters of drive chain links with connecting links, 2 limit switches, 2 emergency stop pushbuttons, and a full set of hydraulic seals) dispatched alongside the machine. Extended warranty packages covering 24 or 36 months are available upon request.
| Option | Description |
|---|---|
| Servo Motor Upgrade | Replace standard AC motor with servo drive for higher positioning accuracy and programmable speed profiling |
| Automatic Stacker | Pneumatic or motorized sheet stacking arm that collects cut sheets and stacks them neatly on a pallet |
| Coil Car System | Motorized coil loading trolley with V-rail track to transport and mount 5–10 ton coils onto the decoiler mandrel |
| Remote IoT Module | 4G/WiFi connectivity module for remote machine status monitoring, production count tracking, and fault alert push notifications |
| Anti-Capillary Groove Roller | Additional forming station on IBR deck to press a water-blocking groove into the side lap edge |
| Stainless Steel Roller Option | Grade 304 or 316L stainless steel rollers for food-grade, marine-environment, or high-corrosion production requirements |
| Flying Cut-Off Saw | Alternative to hydraulic shear; circular saw blade for cutting thicker gauges (0.8–1.2 mm) with clean edge finish |
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