helen@hbxinnuorollforming.com
Forms IBR trapezoidal and corrugated metal sheets from flat steel coil
Two roller decks stacked vertically sharing one motor and cutting unit
Progressive station sequence bends metal gradually into final profile shape
Chrome surface rollers eliminate friction scratches on galvanized coating
PLC programs sheet forming length batch quantity and production line speed
Hydraulic post shear executes clean cut at target length while line runs
Complete turnkey package with decoiler entry table and discharge conveyor
This industrial double layer sheet forming machine transforms flat galvanized or pre-painted steel coil into two types of finished metal roofing panels through a precision cold roll forming process. The upper forming deck is tooled to produce IBR (Inverted Box Rib) trapezoidal profile sheets — structural panels with deep stiffening ribs used for long-span industrial and commercial roofing. The lower deck is configured to form traditional corrugated metal sheets — the classic sinusoidal wave profile that remains the most widely consumed affordable roofing product in developing markets globally. Both forming decks are housed in a single welded structural steel frame and powered by a common drive motor, hydraulic cutting system, and PLC automation controller, delivering two complete production capabilities at a fraction of the cost and floor space of two separate machines.
| Forming Phase | Roller Stations | Metal Deformation Description |
|---|---|---|
| Material Entry and Alignment | Station 1 | Flat steel strip enters the first roller pair which guides and centers the material on the machine axis. Side flange edges begin to form as the strip is constrained laterally. No vertical bending occurs at this stage — the rollers function purely as material guides establishing correct feed orientation |
| Initial Profile Formation | Stations 2–5 | The roller contours begin introducing gentle bends at predetermined rib or wave start positions. Metal deformation is kept well within the elastic-plastic transition zone — approximately 5–10 degrees of bend per station. This gradual approach prevents stress concentration that could cause micro-cracking in the zinc coating layer |
| Progressive Deep Forming | Stations 6–12 | Each successive roller pair deepens the rib channels or wave troughs by an additional 8–12 degrees. Rib side walls steepen; valley floors flatten; wave curvature radius decreases. The metal undergoes controlled plastic deformation distributed across seven stations to achieve uniform grain structure in the bent zones |
| Profile Completion | Stations 13–16 | The final forming rollers set the exact cross-sectional dimensions — rib crest height, valley width, side wall angle, and lap edge profile for IBR sheets; wave amplitude, pitch spacing, and edge contour for corrugated sheets. Springback compensation is engineered into the final station roller geometry |
| Dimensional Calibration | Stations 17–18 | A final sizing roller pair acts as a calibration pass that removes any residual profile deviation. At this point the sheet has achieved its full finished geometry — measured to within ±0.5mm of the engineering profile drawing across the full panel width |
| Roller Attribute | IBR Forming Deck | Corrugated Forming Deck |
|---|---|---|
| Station Count | 14–18 pairs of upper and lower forming rollers | 13–16 pairs of upper and lower forming rollers |
| Base Material | 45# medium carbon forged steel bar stock, ultrasonically inspected for internal soundness | 45# medium carbon forged steel bar stock, ultrasonically inspected for internal soundness |
| Profile Machining | CNC contour turning with custom-ground form tooling; rib profile geometry cut to ±0.05mm tolerance | CNC contour turning with custom-ground form tooling; wave profile geometry cut to ±0.05mm tolerance |
| Heat Treatment | Controlled-atmosphere gas carburizing furnace; oil quench; surface hardness HRC 58–62 with ductile core | Controlled-atmosphere gas carburizing furnace; oil quench; surface hardness HRC 58–62 with ductile core |
| Surface Plating | Industrial hard chrome electroplate; minimum deposit 0.05mm; mirror-grade surface finish | Industrial hard chrome electroplate; minimum deposit 0.05mm; mirror-grade surface finish |
| Mounting Shafts | Φ75–Φ80mm 40Cr alloy steel; precision ground to h7 tolerance; keyway-machined for drive sprocket | Φ75–Φ80mm 40Cr alloy steel; precision ground to h7 tolerance; keyway-machined for drive sprocket |
| Bearing Support | Split cast iron pillow block; double-row self-aligning spherical roller bearing; grease lubricated | Split cast iron pillow block; double-row self-aligning spherical roller bearing; grease lubricated |
| Output Parameter | IBR Sheet Product | Corrugated Sheet Product |
|---|---|---|
| Finished Cover Width | 762mm to 1100mm | 660mm to 1000mm |
| Profile Depth/Height | 28–43mm rib crown elevation | 12–18mm wave crest-to-trough |
| Rib or Wave Count | 4, 5, or 6 trapezoidal ribs | 5, 7, 9, or 11 sinusoidal waves |
| Sheet Length Capability | 1.0m minimum to 14.0m maximum per sheet | 1.0m minimum to 14.0m maximum per sheet |
| Side Joint Configuration | Single overlap with optional anti-capillary groove for enhanced weather sealing | 1.5-wave minimum overlap for weathertight longitudinal joint |
| Input Coil Requirement | 1000–1250mm wide flat strip | 914–1220mm wide flat strip |
| System | Component Detail |
|---|---|
| Welded Main Frame | Heavy-channel longitudinal beams and cross-braced H-beam columns (300H–400H grade structural steel). Entire assembly undergoes post-weld thermal stress-relief annealing to eliminate residual welding stresses. All bearing mounting pads are precision machined after heat treatment to ensure exact shaft centerline alignment across the full roller station array |
| Primary Drive Motor | 5.5kW or 7.5kW AC induction motor, 4-pole, 1440 rpm rated speed, IP54 dust and water spray protected enclosure. Motor selection based on maximum coil gauge and target production throughput specified in the customer order |
| Speed Reduction Gearbox | Worm-type reducer with dual output shafts, oil-bath lubricated. Reduction ratio 1:40 (faster forming for thin gauge) or 1:59 (higher torque for thicker gauge). Dual shafts independently drive the upper and lower deck chain loops |
| Chain Drive Loops | Two independent heavy-duty double-row industrial roller chain circuits. Each chain loop powers one complete forming deck through hardened alloy steel sprockets keyed to every roller shaft. Individual chain tensioner mechanisms allow independent slack adjustment per deck without cross-interference |
| Hydraulic Cutting Assembly | 4.0kW gear-type hydraulic pump motor, 80L oil reservoir with breather filter and temperature gauge, 16–21 MPa system working pressure. Flying shear carriage rides on linear guide rails with pneumatic panel clamp. Cr12MoV cold-work die steel blade set profiled to match the sheet cross-section for clean profile-conforming cuts |
| PLC Automation Package | Central processor (Siemens S7-1200, Delta DVP series, or Mitsubishi FX3U per order), VFD inverter for stepless line speed control, 7-inch or 10-inch color touchscreen HMI with multi-language user interface, rotary pulse encoder on final shaft for real-time length tracking, mechanical limit switches at shear carriage home and over-travel positions, three emergency stop stations along the production line |
| Station | Equipment | Function in the Sheet Forming Line |
|---|---|---|
| 1 | Hydraulic Mandrel Uncoiler | Supports steel coil on expanding hydraulic jaws with 5-ton or 8-ton load rating. Brake system provides adjustable drag resistance for uniform strip tension during pay-off into the forming section |
| 2 | Entry Alignment Table | Adjustable-width side guide roller assembly centers the incoming strip on the machine axis. Integrated manual guillotine pre-shear blade squares the coil leading edge before entry into the forming deck |
| 3 | Double Layer Main Forming Unit | Core forming station housing the upper IBR roller deck and lower corrugated roller deck. Pivoting diverter plate at the entry side directs the strip into either deck. Both decks share the motor, gearbox, chain drive loops, hydraulic shear, and PLC controller |
| 4 | Flying Hydraulic Post-Shear | Mounted at the forming machine exit. Shear carriage accelerates to match line speed, pneumatic clamp grips the formed sheet, hydraulic cylinder drives the profiled blade through the panel cross-section, then carriage and blade retract to home — all while the line continues producing without interruption |
| 5 | PLC Electrical Control Enclosure | IP54 rated steel cabinet containing PLC processor, VFD inverter, electrical relays, motor overload protectors, circuit breakers, and terminal connection blocks. External touchscreen HMI mounted on cabinet door or separate operator pedestal |
| 6 | Discharge Roller Conveyor | 3–5 meter free-roller receiving table with adjustable-height support legs. Collects finished cut sheets as they exit the shear and supports them for manual stacking, bundling, and dispatch preparation |
| Specification Parameter | Value |
|---|---|
| Raw Material Compatibility | Hot-dip galvanized steel (GI Z60–Z275), pre-painted galvanized iron (PPGI PE/SMP/PVDF), aluzinc/Galvalume AZ150–AZ200, cold-rolled steel strip, aluminum 1100/3003 alloy sheet |
| Material Thickness Processing Range | 0.25mm to 0.80mm (approximately 30-gauge through 20-gauge) |
| Material Yield Strength Limit | 200 MPa to 400 MPa (mild steel grades through structural grades) |
| Forming Line Speed | 10–18 meters per minute; stepless variable adjustment via VFD inverter control interface |
| Sheet Cut Length Accuracy | ±1.0mm at any programmed length via rotary encoder real-time feedback to PLC auto-correction algorithm |
| Profile Switching Method | Manual pivoting diverter plate repositioning; IBR-to-corrugated changeover completed in approximately 10–15 minutes including strip re-threading |
| Electrical Power Input | 380V 50Hz 3-phase standard; custom voltage and frequency (220V/415V/440V/480V, 50Hz/60Hz) configured per destination country requirements |
| Total Installed Power | Approximately 10–12 kW (main drive motor + hydraulic pump motor combined) |
| Machine Dimensions (L×W×H) | Approximately 7.0–8.0m × 1.4–1.6m × 1.7–2.0m depending on roller station count and frame specification |
| Machine Net Weight | 5.0 to 7.5 metric tons according to profile configuration, roller count, and frame grade |
| Decoiler Coil Capacity | 5 metric tons standard or 8 metric tons heavy-duty per customer specification |
| Coil Inner Diameter | Φ508mm standard; Φ610mm with decoiler mandrel adapter sleeve available |
| No. | Operation | Action Description |
|---|---|---|
| 1 | Coil Mounting | Steel coil crane-lifted onto the hydraulic uncoiler mandrel; expansion jaws engage and lock the coil inner bore; brake resistance set to deliver controlled strip tension throughout the forming cycle |
| 2 | Strip Threading | Coil leading edge fed through adjustable entry side guide rollers to achieve centerline alignment; manual pre-shear guillotine trims the coil head square before insertion into the selected roller deck entrance |
| 3 | Deck Selection | Operator pivots the diverter guide plate — upward orientation directs the strip into the upper IBR forming deck; downward orientation routes it into the lower corrugated forming deck. Deck changeover from one profile to the other takes approximately 10 minutes |
| 4 | Sequential Roll Forming | The flat strip advances through the complete series of roller station pairs; at each station the metal undergoes incremental bending until, emerging from the final station pair, the sheet has achieved its fully formed IBR trapezoidal rib geometry or complete corrugated sinusoidal wave contour |
| 5 | Length Monitoring | A rotary pulse encoder coupled to the final forming shaft continuously transmits digital signals to the PLC processor; the controller compares the real-time accumulated pulse count against the operator-programmed target sheet length value |
| 6 | Automated Shear Cut | Upon reaching the target length, the PLC initiates the cut sequence: pneumatic clamp grips the formed sheet → shear carriage accelerates to synchronized line speed → hydraulic cylinder drives the profiled Cr12MoV blade through the panel cross-section → blade retracts and carriage returns to home position — all executed without pausing the forming line |
| 7 | Finished Sheet Handling | The separated formed sheet slides onto the free-roller discharge conveyor; the operator lifts each finished panel and stacks it onto the product pallet or bundle for strapping, inventory storage, and delivery to the customer |
| Comparison Element | Two Independent Single-Layer Forming Lines | One Double Layer Forming Line |
|---|---|---|
| Equipment Purchase Cost | 100% — total price of two complete forming machines plus two decoilers | Approximately 65–75% of the two-unit total expenditure |
| Factory Floor Space Required | 44–70 square meters for both production lines | 20–35 square meters for the single dual-output line |
| International Container Shipping | Two 20GP containers, two separate ocean freight charges | One 20GP or 40HQ container, one consolidated freight invoice |
| Foundation and Utility Installation | Two concrete machine pads, two electrical supply drops, two cable runs | One concrete machine pad, one electrical supply drop, one cable run |
| Production Operator Count | 3–4 workers across two separate forming lines | 1–2 workers for one dual-deck forming line per shift |
| Energy Operating Expense | Two drive motors and two hydraulic pumps drawing power continuously | One drive motor and one hydraulic pump — approximately 40% reduction in electricity consumption |
| Spare Parts Inventory Requirement | Two complete sets of wearing components in warehouse stock | One spare parts set services both forming decks |
Before export crating, each completed sheet forming machine passes through an exhaustive three-phase quality verification process. Phase one — dimensional inspection: all roller gaps are measured at every forming station using calibrated feeler gauges and compared against the engineering tolerance specification; shaft runout is verified with dial test indicators at each bearing position; frame level and square are confirmed with precision spirit levels and cross-laser alignment instruments. Phase two — extended no-load operation: the machine runs without material at maximum rated speed continuously for a minimum of four hours; bearing housing temperatures are monitored and recorded at 30-minute intervals using infrared thermometers; chain drive engagement is checked visually and audibly for smooth, even tooth meshing; the PLC controller is cycled through every programmed function — power-up, motor start, speed adjustment, length value input, batch quantity programming, recipe recall, emergency stop activation, and restart sequencing — to confirm complete system integration and fault-free operation. Phase three — live production trial: factory technicians load genuine galvanized steel coil stock and produce 50 IBR sheets followed by 50 corrugated sheets; every 10th panel is measured for sheet length, rib geometry or wave pitch, and cut edge quality using calibrated digital measuring instruments. Only machines recording zero out-of-tolerance measurements across all three inspection phases are cleared for export packaging and container loading.
The main forming machine body undergoes comprehensive protective packaging in three layers: an inner wrap of VCI (volatile corrosion inhibitor) anti-rust film; a middle layer of high-density closed-cell foam padding at all corners, edges, and protruding machine components; an outer wrap of heavy-gauge UV-stabilized polyethylene shrink film for moisture, dust, and handling protection during ocean transit. The wrapped assembly is bolted through its base frame to a fumigated ISPM-15 certified plywood pallet or welded structural steel export skid. All auxiliary equipment items — hydraulic uncoiler, discharge roller conveyor, hydraulic power unit, and electrical control cabinet — are individually packed in purpose-built marked fumigated wooden crates with internal foam bracing and bolted tie-downs. A separate accessories crate contains the operator hand tool kit, spare wearing parts starter pack, and the complete printed technical documentation set: mechanical assembly drawings with exploded component identification views, electrical wiring schematic with terminal and wire number labeling, PLC parameter configuration reference guide, daily and weekly lubrication schedule with recommended grease types, and a comprehensive English-language operation and maintenance manual. Manufacturing lead time is 25–35 working days from receipt of the deposit payment and customer-signed profile approval drawings. Standard warranty coverage is 12 months from the date of shipment.
| Optional Feature | Description and Operational Benefit |
|---|---|
| Servo Motor Drive Conversion | Replace standard AC induction motor with programmable servo drive for precision-controlled acceleration and deceleration, enhanced sheet length accuracy, and reduced energy consumption during intermittent production cycles |
| Automatic Sheet Stacking System | Motorized stacking arm transfers finished formed sheets from the discharge conveyor to neatly aligned bundles on a pallet, eliminating manual sheet handling labor and reducing operator fatigue |
| Battery-Powered Coil Loading Cart | Electric trolley on floor-mounted guide rails with hydraulic scissor lift platform; transports steel coils up to 10 tons from warehouse storage to the uncoiler mandrel without requiring an overhead crane |
| IoT Production Monitoring Gateway | 4G cellular-connected module transmits real-time production data — daily sheet count, motor operating hours, fault diagnostic codes, and preventive maintenance interval alerts — to a dedicated smartphone application or web-based dashboard |
| Custom Embossing Roller Insert | Specially engraved forming roller pair that permanently imprints a manufacturer brand name, company logo, or production date code into each sheet as it passes through the forming sequence |
| 304/316L Stainless Steel Roller Upgrade | Complete forming roller set manufactured from austenitic stainless steel for sheet forming operations in food-grade processing plants, pharmaceutical production facilities, chemical industry environments, or high-salinity coastal manufacturing locations |
