OEM Double Layer Roll Forming Machines

 

OEM double layer roll forming machines are industrial equipment used to bend metal sheets into customized profiles. This comprehensive guide provides a detailed overview of double layer roll formers covering working principles, main components, design considerations, customization options, suppliers, installation, operation, maintenance and more.

 

What Are OEM Double Layer Roll Forming Machines?

 

OEM double layer roll forming machines continuously bend and form metal coils into customized profiles with two layered sections. They create complex symmetrical and asymmetrical shapes by progressively rolling sheets through a series of roller dies.

 

Key highlights of double layer roll formers:

 

• Produce two-layer wall panel profiles in one forming process
• Deliver high production efficiency and accuracy
• Automated operation for mass production scenarios
• Ideal for roofing, walling, façade and gate manufacturing
• Enable inline punching, drilling and other secondary processing
• Fully customizable end-profiles based on application

 

Table 1: Types of OEM Double Layer Roll Formers

 

Type	Description
Standard	Basic machine for general double layer profiles  Fixed forming and processing modules
Customized	Tailored configuration per profile design  Interchangeable forming sections
PLC Control	Touchscreen and PLC automation  Monitoring, troubleshooting and parameter control
Servo Motor	Advanced servo motor drive system  Precise speed/tension control, quick roll changes

 

How Do Double Layer Roll Forming Machines Work?

 

Double layer roll formers bend and cut metal strips to create two separate C or U channels in one forming operation. They then bring together and interlock the channels to produce hollow, rigid profiles.

 

The step-by-step working process is outlined below:

 

1. Material Feeding: Coiled raw material loaded onto a de-coiler which feeds into the forming sections at a controlled speed and tension.

2. Pre-processing: Sheet goes through a series of punching, drilling, notching and embossing dies to add features.

3. Primary Forming: The strip gets formed into a C or U shape using horizontal and vertical rolls.

4. Secondary Forming: Separate set of rolls create a second C/U channel moving synchronously.

5. Profile Joining: The two formed channels brought together and interlocked to create hollow final profile.

6. Post-processing: Additional inline processes done like hole punching or embossing on final profile.

7. Cutting: Profile cut to specified lengths by built-in cutoff press or flying shear system.

8. Stacking: Conveyors transfer cut profiles for automatic stacking before final inspection.

 

Table 2: Main Components of Double Layer Roll Forming Machines

 

Component	Description
De-coiler	Feeds raw material into line from coils
Variable speed drives	Controls material speed into the forming sections
Punching units	Create holes or slots on the strips
Forming rolls	Progressively bend metal sheet into C/U channels
Joining Bridge	Brings together two formed channels and interlocks them
Flying shear/Cutoff shear	Cuts final profile to length
Hydraulic system	Applies precision pressure to forming rolls
Control panel	Houses PLC and HMI for controlling devices
Conveyor system	Transfers cut profiles for stacking/bundling

 

Key Design Aspects And Customization

 

Double layer roll formers can be fully tailored to produce custom profiles based on specifications:

 

Table 3: Customization Options for OEM Double Layer Roll Forming Machines

 

Factor	Design Choices
Material type	Mild steel, stainless steel, aluminum etc.
Material thickness	20 gauges to 5 mm
Profile dimensions	Per application standards
Layer symmetry	Symmetrical/asymmetrical shapes
Embossing patterns	Various aesthetic effects
Processing tools	Punching, drilling, tapping, notching, deburring etc.
Secondary operations	Corner welding, stud welding, spray painting etc.
Length tolerance	As per precision requirements
Debugging tools	Linear encoder, PLC data monitoring etc.
Climate specifications	General, humid, coastal, desert etc.

The profile design process involves:

 

• Finalizing product drawings and 3D models
• Calculating length of strip needed for each shape
• Mapping sequence of roller dies to achieve progressive bends
• Determining punching design, shear placement etc.
• Simulating forming process using software
• Building and testing tooling on sample materials
• Refining machine configuration for mass production
• Options like servo motor drives for quick roll changes

 

Choosing OEM Double Layer Roll Former Suppliers

 

Many heavy machinery manufacturers offer customizable double layer roll forming lines:

 

Table 4: OEM Double Layer Roll Former Manufacturers

 

Company	Location	Contact
SUNWAY	China	web: www.rollformingmachine.com  email: sales@wuxisunway.com
FONNTAI	China	web: fontai.cn  email: fontai@fontaimachine.com
Shanghai Metal Corporation	China	web: www.shanghaimetal.com  email: smc@shanghaimetal.com
ZHENGGONG	China	web: www.zgrollformingmachine.com  email: machine@zgrollformingmachine.com

Key factors to evaluate potential suppliers on:

 

• Years of experience
• Domain expertise
• Design consultation process
• Flexibility for customization
• Tooling development capabilities
• Production capacity
• International quality certifications
• Scope of after-sales support

 

Table 5: Price Range of OEM Double Layer Roll Formers

 

Speed (m/min)	Forming Capability (mm)	Layers	Approximate Price Range
5 – 10	1.5 – 2.5	Double layer	$30000 – $50000
10 – 40	1.5 – 3	Double layer	$40000 – $80000
40 – 80	2.5 – 4	Double layer	$50000 – $100000

Pricing varies based on factors like capacity, automation level, secondary processing capability etc.

 

 

Installation And Implementation

 

Installing an OEM double layer roll former requires extensive pre-planning:

 

Table 6: Roll Former Installation Procedure

 

Stage	Actions
Site Preparation	Ensure adequate space, level concrete floors to take heavy loads <br> Set up power supply lines, hydraulic piping, compressed air etc.
Unpacking	Unload machine modules safely with cranes avoiding damage
Position Alignment	Assemble sections perfectly aligned to each other to prevent skew
Levelling	Precision levelling of entire line very important for proper material flow
Commissioning Trials	Initial test runs with multiple adjustments to hydraulic pressure etc.
Trial Production	Vary operating factors and fine tune for achieving design quality parameters <br> Observe deformations, thickness variations, twisting and rectify
Final Alignment Check	Recheck alignment of de-coiler, roll stations, cutoff shear etc.

Apart from mechanical factors, the forming quality depends heavily on:

 

• Sheet metal properties like hardness, rigidity, internal stresses etc. affecting response to rolling loads
• Surface preparation to enable smooth low-friction material flow
• Lubrication quality and temperature uniformity
• Automated feedback loops for precision monitoring and control

 

Maintenance Practices

 

Like any heavy machinery, regular preventive maintenance improves longevity and performance of double layer roll formers:

 

Table 7: Maintenance Schedule for Double Layer Roll Forming Machines

 

Frequency	Activities
Daily	Visual inspection of roll bearings, fluid levels  Verify fastener tightness  Monitor drive system temperature
Weekly	Thorough cleaning of roll surfaces, scrapers  Inspect key mechanical synchronizations
Monthly	Lubricate bearings, gearboxes, shafts  Calibrate sensors and gauges
Quarterly	Check flatness of levelling pads  Repair worn out roll bearings/rollers
Yearly	Complete re-alignment checks  Varnish electrical cabinets to prevent rusting  Training programs for employees on safety procedures

Proper storage of unused tooling also prevents deterioration when changing profiles frequently.

 

Key maintenance tips:

 

• Schedule downtime maintenance with production planning
• Ensure sufficient spares inventory
• Keep historical log of parameter changes
• Upgrade hydraulic, coolant and filtration systems
• Automate condition monitoring and diagnostics
• Treat as capital investment with continuous improvements

 

Operating Principles

 

Operators need training for working safely with OEM double layer roll formers:

 

Table 8: Operating Guidelines for Roll Forming Machines

 

Steps	Description
Safety Gear	Wear gloves, ear protection, covered shoes at all times
Lockout/Tagout	De-energize all circuits before physical intervention
Material Loading	Use proper equipment for lifting heavy coils
Threading	Carefully pass strip through without scratches or buckles
Startup Sequence	Turn auxiliary motors on first before engaging drive
Idle Running	Let reach operating temperature; check for abnormalities
Speed Control	Gradually accelerate to production speed monitoring strip flow
Visual Monitoring	Observe strip scrolling for defects or deviations
Parameter Changes	Vary factors like roller pressure/balance slowly
Emergency Shutdown	Regularly test all stop and safety circuits

Key operating principles:

 

• Allow proper machine warmup cycles during startup and after prolonged stops
• Ensure heads of fasteners are properly positioned before applying drive power
• Have detailed operating manuals from supplier onsite for reference
• Collect production quality data in standard formats for analysis
• Follow recommended parameters for lubrication, temperature zones etc.
• Maintain tidy work-space and steady material supply flows

 

Pros And Cons Of Double Layer Roll Forming Machines

 

Table 9: Advantages of double layer roll forming process

 

Benefits	Details
High production rate	Up to 100 m/min with automated stacking
Superior strength profiles	Double layers provide better reinforcement
Built-in stiffeners	Interlocks between channels enhance rigidity
Material savings	Less overlap and wastage during forming
Shape intricacy	Capable of asymmetric and unconventional forms
Secondary processing	Inline hole punching, notching possible
Dimensional accuracy	Consistent tolerance control via automation
Operator safety	Closed forming modules guard rotating parts

Table 10: Limitations of double layer roll forming process

 

Drawbacks	Details
High tooling costs	Specialized roller dies needed for each profile
Skilled labor for maintenance	Troubleshooting forming issues requires expertise
Potential twisting	Improper joining can skew final shape
Expensive changes	Significant rework for new profiles
Floor-space requirements	Limitations for extremely long machines
Limited bend radii	Restricts severely curved designs
Noise hazards	Precautions needed against acoustic impacts

While the double layer roll forming process has some inherent restrictions, OEM manufacturers continue to incorporate advanced servo control, quick-change tooling and monitoring sensors to mitigate limitations.

 

Applications Of OEM Double Layer Roll Formed Profiles

 

Double layer roll forming technology enablesfolded metal structures ideal for:

 

Cladding and Wall Elements: Multi-layer wall panels, built-up roofing sheets etc.

 

Structural Framing: Lightweight purlins, channels, equipment racks used extensively in prefab buildings, solar mounts etc.

 

Furniture: Chairs, shelves, racks, lockers and storage units etc. gain durability.

 

Automotive: Railway carriage framing, truck body panels, commercial vehicle floors and compartments etc. benefit from interlocked hollow strength.

 

Storage Infrastructure: Warehouse partitions, mezzanine flooring, silo linings use these cold roll formed sections.

 

Agricultural Infrastructure: Grain silos, greenhouse structures, animal husbandry shelters etc. employ interlocking wall and roof cladding profiles.

 

Domestic Appliances: Air conditioner chassis, refrigerator panels etc. apply double layer frames.

 

Customized Gates and Railings: Ornamental entrance gates combine aesthetics along with intrusion resistance.

 

Multilayer roll formed components serve lightweight, high-strength demands across manufacturing industries.

 

 

Frequently Asked Questions

 

Q: What thickness of sheets can be formed on double layer roll formers?

 

A: Standard machines accommodate material thickness from 0.7mm to 2.5mm. Heavy-duty lines go up to 8mm thickness. Customized tooling allows even thicker plates.

 

Q: How to decide appropriate production line speed?

 

A: Recommended operating speed falls between 10-100m/min depending on metal alloy type, thickness, desired product quality, and extent of secondary processing.

 

Q: What sheet metal types can be roll formed?

 

A: Mild steel is commonly used, but stainless steel, aluminum alloys, brass, copper etc. can also be easily formed. Special surface coatings or tempering may be required beforehand.

 

Q: What degree of profile customization is possible?

 

A: Complete custom profiles are possible matching 3D models. Limiting factors may be minimum bend radii, corner interlocks and avoiding shape distortions.

 

Q: Can standard catalog profiles be mass produced?

 

A: Yes absolutely. Standard window/door frames, roofing sheets, drywall profiles etc. can be mass produced at the highest volumes matching industry standards.

 

Q: How to minimize per piece cost for mass orders?

 

A: Automating stacking, bundling and integrating before downstream processes like welding/painting helps minimize cost by reducing manual labor significantly.

 

Q: What is the largest length that can be continuously formed?

 

A: Some leading manufacturers develop super-long machines exceeding 60 meters in forming length. But typically 25-30 meters is maximum before requiring special intermediate supports.

 

Q: How much space is required for installing these machines?

 

A: Approximate sizing guidelines:

 

• Length = Raw material supplier coil diameter + Machine length + Shearing buffers
• Width = Roll forming sections width + 1.5m minimum safe passageways on both sides
• Height = Tallest section height with 1m clearance

 

Provide 15-20% extra space for safe movement.