helen@hbxinnuorollforming.com
One machine forms IBR and corrugated roofing sheets from flat coil
Two roller decks stacked vertically share common frame and drive
Progressive bending stations gradually shape metal into roof profiles
Hard chrome rollers prevent zinc coating damage during sheet forming
PLC controls forming speed sheet length and automatic batch counting
Hydraulic shear cuts formed roofing panel at target length on the fly
Full line with decoiler entry guide and run-out table in one shipment
This industrial double layer roll forming machine converts flat galvanized or pre-painted steel coil into finished IBR trapezoidal roofing sheets and traditional corrugated roofing sheets through a precision cold-forming process. The machine carries two complete roller tooling sets in a vertical stacked arrangement — the upper set dedicated to IBR rib profile forming and the lower set configured for sinusoidal wave corrugated profile forming. A single drive motor, shared hydraulic cutting unit, and unified PLC automation system power both roller decks, giving roofing sheet manufacturers the ability to produce two distinct product lines from one compact forming station.
| Forming Stage | What Happens to the Metal Strip | Engineering Purpose |
|---|---|---|
| Entry (Station 1–2) | Flat strip is received from the decoiler and guided into the first roller pair; edges are aligned and the strip is centered on the machine axis | Establishes material position and prevents lateral drift that would cause asymmetric forming |
| Initial Bend (Station 3–5) | First forming rollers apply gentle downward pressure at rib or wave start points; metal begins to curve at predefined bend lines | Creates the primary fold lines without exceeding the material's elastic limit too abruptly |
| Progressive Forming (Station 6–12) | Each successive roller pair increases the bend angle incrementally by 8–15 degrees per station; ribs deepen and valleys flatten simultaneously | Distributes the total deformation across multiple gradual steps to prevent metal cracking, wrinkling, or springback |
| Profile Finishing (Station 13–16) | Final roller pairs set the exact rib height, valley width, and side-lap geometry; the profile reaches its final engineered cross-section | Achieves dimensional accuracy within ±0.5mm of the design profile; compensates for material springback |
| Calibration (Station 17–18) | Last roller pair acts as a sizing pass; minor adjustments fine-tune the profile shape and ensure consistent output panel after panel | Guarantees panel-to-panel uniformity so every roofing sheet stacks and installs identically on the building structure |
| Tooling Attribute | IBR Forming Tooling | Corrugated Forming Tooling |
|---|---|---|
| Number of Forming Stations | 14–18 progressive roller pairs | 13–16 progressive roller pairs |
| Roller Material | 45# forged medium carbon steel billet, CNC contour-turned | 45# forged medium carbon steel billet, CNC contour-turned |
| Profile Geometry Machined | Trapezoidal rib with flat valleys and angled side walls | Continuous sinusoidal wave curvature with uniform radius |
| Surface Treatment | Gas carburizing case hardening + hard chrome electroplate 0.05–0.08mm | Gas carburizing case hardening + hard chrome electroplate 0.05–0.08mm |
| Roller Hardness | HRC 58–62 surface, tough ductile core | HRC 58–62 surface, tough ductile core |
| Shaft Diameter | Φ75–Φ80mm 40Cr alloy steel, precision ground | Φ75–Φ80mm 40Cr alloy steel, precision ground |
| Bearing Support | Split pillow block, double-row self-aligning, grease-lubricated | Split pillow block, double-row self-aligning, grease-lubricated |
| Gap Adjustment | Individual screw-down mechanism per station, 0.05mm resolution | Individual screw-down mechanism per station, 0.05mm resolution |
| Output Specification | IBR Roofing Sheet | Corrugated Roofing Sheet |
|---|---|---|
| Effective Cover Width | 762 / 840 / 925 / 1000 / 1050 / 1100 mm | 660 / 750 / 800 / 900 / 1000 mm |
| Profile Height (Depth) | 28–43 mm from valley floor to rib crest | 12–18 mm crest-to-trough total amplitude |
| Rib or Wave Count | 4, 5, or 6 ribs per panel | 5, 7, 9, or 11 waves per panel |
| Panel Length Range | 1.0 m minimum to 14.0 m maximum | 1.0 m minimum to 14.0 m maximum |
| Side Lap Detail | Single overlap, optional anti-capillary groove | 1.5-wave minimum overlap for weather seal |
| Input Coil Width | 1000–1250 mm flat strip | 914–1220 mm flat strip |
| Machine Section | Construction Detail |
|---|---|
| Main Chassis Frame | Heavy welded structural steel assembly using channel and H-beam sections (300H–400H grade); post-weld thermal stress-relief annealed in industrial furnace; bearing mounting surfaces precision machined after heat treatment for guaranteed shaft alignment across all roller stations |
| Drive Motor Assembly | 5.5kW or 7.5kW AC induction motor, 4-pole, IP54 enclosed; directly coupled to a worm-type dual-output speed reducer with oil-bath lubrication; reduction ratio 1:40 or 1:59 depending on sheet gauge and speed requirements |
| Power Distribution | Two independent heavy-duty double-row industrial roller chain loops, one per forming deck; each loop driven from a separate output shaft of the common gearbox; hardened alloy steel sprockets on every roller shaft; individual chain tension adjusters per loop |
| Hydraulic Cutting Assembly | 4.0kW gear-type pump motor, 80-liter oil reservoir with breather filter and sight glass, 16–21 MPa system pressure; flying shear carriage rides on linear guide rails; pneumatic clamp holds the sheet during cut cycle; Cr12MoV die steel blade set profiled to roofing sheet cross-section |
| Electrical Control System | PLC central processor (Siemens S7-1200, Delta DVP, or Mitsubishi FX3U per order), VFD inverter for stepless forming speed regulation, 7-inch or 10-inch color touchscreen HMI, rotary pulse encoder on final shaft for real-time length measurement, mechanical limit switches for shear carriage home and over-travel positions, three emergency stop pushbuttons along the line |
| Sequence | Equipment Unit | Role in the Forming Process |
|---|---|---|
| 1 | Hydraulic Mandrel Decoiler | Holds the flat steel coil; expanding hydraulic jaws grip the inner bore; brake mechanism provides controlled resistance to maintain consistent strip tension feeding into the forming section |
| 2 | Entry Guide with Pre-Shear | Adjustable side roller rails center the strip on the machine axis; manual guillotine blade trims the coil leading edge square prior to threading into the roller deck entrance |
| 3 | Double Layer Forming Main Machine | Core forming unit where upper IBR roller deck and lower corrugated roller deck progressively shape the flat strip into finished roofing sheets; pivoting diverter plate selects which deck receives the material |
| 4 | Flying Hydraulic Post-Cut Station | Shear carriage travels synchronously with the moving formed sheet; hydraulic cylinder drives the profiled blade through the panel cross-section at exactly the programmed length |
| 5 | PLC Control Cabinet | Central automation enclosure housing the PLC processor, VFD inverter, electrical relays, overload protectors, and circuit breakers; external touchscreen panel for operator programming and monitoring |
| 6 | Run-Out Roller Table | Free-roller conveyor that receives cut roofing sheets as they exit the shear; adjustable-height legs position the table for ergonomic manual panel collection and stacking |
| Specification Parameter | Data |
|---|---|
| Suitable Input Materials | Hot-dip galvanized steel coil (Z60–Z275), pre-painted galvanized iron (PPGI with PE/SMP/PVDF), aluzinc/Galvalume AZ150–AZ200, cold-rolled steel strip, aluminum alloy 1100/3003 sheet |
| Material Gauge Processing Range | 0.25 mm to 0.80 mm (approximately 30-gauge to 20-gauge equivalent) |
| Material Yield Strength Range | 200–400 MPa (covers mild steel through structural grades) |
| Forming Line Speed | 10–18 meters per minute, stepless variable adjustment via VFD inverter control dial |
| Panel Length Accuracy | ±1.0 mm at any programmed length through encoder feedback and PLC auto-correction |
| Profile Switchover Time | Approximately 10–15 minutes including diverter plate repositioning and strip re-threading into the alternate deck |
| Electrical Power Input | 380V 50Hz 3-phase standard; custom voltage (220V/415V/440V/480V) and frequency (50Hz/60Hz) configured to destination country |
| Total Installed Power | Approximately 10–12 kW combined (main drive motor 5.5/7.5kW + hydraulic pump 4.0kW) |
| Machine Dimensions (L×W×H) | Approximately 7.0–8.0 m × 1.4–1.6 m × 1.7–2.0 m depending on roller station count and frame specification ordered |
| Machine Net Weight | 5.0–7.5 metric tons according to profile configuration and frame grade selected |
| Decoiler Coil Capacity | 5 metric tons or 8 metric tons depending on uncoiler model chosen |
| Coil Inner Diameter | Φ508 mm standard; Φ610 mm available with decoiler mandrel adapter sleeve |
| Step | Operation | Action Detail |
|---|---|---|
| 1 | Coil Setup | Steel coil lifted onto the hydraulic decoiler mandrel; expansion jaws engage the coil inner bore with firm grip; brake tension set to provide steady strip resistance during pay-off without over-tensioning |
| 2 | Strip Threading | Coil leading edge guided through adjustable entry side rollers for centerline alignment; manual pre-shear guillotine trims the coil head square before feeding into the roller deck |
| 3 | Deck Routing | Operator positions the pivoting diverter plate — angled upward feeds the upper IBR forming deck, angled downward feeds the lower corrugated forming deck. Deck changeover completed in approximately 10 minutes |
| 4 | Progressive Forming | Flat strip advances through each roller station pair sequentially; at every station the metal is bent a few additional degrees until, emerging from the final station, it has reached the complete IBR trapezoidal rib geometry or full corrugated sinusoidal wave profile |
| 5 | Length Tracking | Rotary pulse encoder on the final drive shaft transmits continuous digital signals to the PLC processor; the controller compares the accumulated pulse count in real time against the operator-entered target sheet length |
| 6 | Flying Cut Cycle | At target length the PLC activates the sequence: pneumatic clamp grips the sheet → shear carriage accelerates to match line speed → hydraulic cylinder drives the profiled blade through the panel → blade retracts → carriage returns to home position — all without stopping the forming line |
| 7 | Panel Collection | The separated roofing sheet slides onto the free-roller run-out conveyor; operator lifts each finished panel and stacks it onto the product pallet or bundle for strapping, storage, and dispatch |
| Comparison Criterion | Two Separate Single-Profile Forming Lines | One Double Layer Forming Line |
|---|---|---|
| Equipment Investment | 100% — full purchase price of two machines plus two decoilers | Approximately 65–75% of the two-machine total cost |
| Factory Floor Occupation | 44–70 square meters for both production lines | 20–35 square meters for one line |
| Container Shipping | Two 20GP containers, two ocean freight invoices | One 20GP or 40HQ container, one freight invoice |
| Civil and Electrical Works | Two concrete foundation pads, two power drops | One concrete foundation pad, one power drop |
| Production Labor | 3–4 operators across two forming lines | 1–2 operators per production shift |
| Energy Operating Cost | Two motors and two hydraulic pumps drawing power | One motor and one hydraulic pump — approximately 40% less electricity |
| Spare Parts Requirements | Two complete sets of wearing components in inventory | One set covers both roller decks |
Before export packaging, every completed forming machine undergoes a rigorous three-phase inspection procedure. Phase one — dimensional verification: all roller gaps are measured at each station with calibrated feeler gauges and checked against the engineering tolerance table; shaft runout is verified with dial test indicators at every bearing position; frame levelness and squareness are confirmed using precision spirit levels and laser alignment tools. Phase two — extended dry operation: the machine runs continuously at maximum rated speed without material for a minimum of four hours; bearing housing temperatures are monitored and recorded at 30-minute intervals using infrared thermometers; chain engagement is inspected visually and audibly for smooth tooth meshing; the PLC controller is cycled through every programmed function — startup, speed adjustment, length input, batch counting, recipe recall, emergency stop, and restart — to validate full system integration. Phase three — live production testing: factory technicians load actual galvanized steel coil and produce 50 consecutive IBR roofing sheets followed by 50 consecutive corrugated roofing sheets; every 10th panel is measured for length, rib geometry, wave pitch, and cut-edge quality using calibrated digital instruments. Only machines that pass all three phases with zero measurements beyond the published tolerance range are approved for export crating and container loading.
The main forming machine body receives comprehensive three-layer protective packaging: an inner wrap of VCI (volatile corrosion inhibitor) anti-rust film; middle layer of high-density foam padding at all corners, edges, and protruding components; outer wrap of heavy-gauge UV-stabilized polyethylene shrink film for moisture and dust protection. The wrapped unit is bolted through its base frame to a fumigated ISPM-15 compliant plywood pallet or welded structural steel export skid. All auxiliary equipment — hydraulic decoiler, run-out roller conveyor, hydraulic power pack, and electrical control cabinet — is individually packed in marked, fumigated wooden crates with internal foam bracing and bolted tie-downs. A dedicated accessories crate contains the operator hand tool kit, spare wearing parts starter pack, and one complete printed set of technical documentation. Manufacturing lead time is 25–35 working days from confirmed deposit receipt and customer-signed profile approval drawings. Standard warranty coverage is 12 months from the bill of lading date; a 24-month extended warranty option is available for purchase.
| Optional Item | Function and Benefit |
|---|---|
| Servo Motor Drive Package | Programmable acceleration and deceleration curves for gentler sheet handling; higher length precision; reduced energy usage during intermittent forming cycles |
| Automatic Panel Stacking System | Motorized stacking mechanism transfers finished roofing sheets from the run-out table to neat aligned bundles on a pallet, eliminating manual sheet handling labor |
| Powered Coil Loading Trolley | Battery-operated cart on floor-mounted guide rails with hydraulic scissor lift; transports steel coils up to 10 tons from warehouse storage to the decoiler mandrel without crane assistance |
| IoT Remote Monitoring Module | 4G cellular-connected device transmits real-time production metrics — daily panel count, motor operating hours, fault diagnostic codes, and preventive maintenance interval reminders — to a smartphone app or web dashboard |
| Custom Embossing Roller Set | Custom-engraved roller station that permanently imprints a brand name, manufacturer logo, or production date code into each roofing sheet during the forming process |
| 304/316L Stainless Roller Upgrade | Complete roller set manufactured from austenitic stainless steel for forming roofing sheets destined for food-grade facilities, pharmaceutical plants, chemical processing environments, or high-salinity coastal locations requiring corrosion-proof tooling |
