Product Overview
The Heavy Gauge Z Purlin Roll Forming Machine produces high-strength Z-shaped structural purlins from steel coil through continuous roll forming, hydraulic punching, and cut-to-length operations. Designed for heavy structural applications, it features an anti-springback station design, reinforced shafts, and a fully automatic PLC-driven width changeover system to maximize uptime.
Technical Specifications
|
Specification Item |
Heavy-Gauge Standard Configuration |
|
Material Thickness |
2.0 to 4.0 mm |
|
Compatible Materials |
Cold rolled steel, hot rolled steel, galvanized steel, high-tensile steel (up to Q355 / G550) |
|
Forming Speed |
10 to 20 m/min (depending on thickness and punching layout) |
|
Forming Stations |
16 to 22 progressive stands |
|
Main Shaft Diameter |
Diameter 85 to 95 mm (40Cr heavy-duty alloy, quenched and tempered) |
|
Main Transmission |
Heavy-duty individual gearbox / chain drive transmission |
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Main Motor Power |
22 to 30 kW |
|
Control System |
PLC + Touchscreen HMI (Multi-language support) |
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Length Tolerance |
+/- 1.0 mm (at standard continuous production) |
|
Electrical Requirement |
380V / 50Hz / 3-Phase (customizable per site location) |
Key Product Advantages
Heavy-Duty Capability: Engineered for 2.0–4.0 mm high-strength steel (up to S550GD). Built with Ø 85–95 mm solid shafts, heavy H-beam frames, and gearbox drives to eliminate deflection under maximum loads.
Anti-Springback Tooling: Uses 18–24 station CNC-machined Cr12MoV/GCr15 quenched rollers with over-bending pass design to control material springback, ensuring section straightness and strict tolerances (±1.0 mm).
Fast PLC Size Changeover: Fully motorized web and flange adjustment via Siemens touchscreen switches purlin sizes in under 10 minutes, cutting setup downtime.
High-Efficiency Punching & Cutting: Integrates Yuken hydraulics and optional Yaskawa servo drives with non-stop flying shear technology for continuous high-speed output (up to 20 m/min).
Applications
Heavy-gauge Z purlins serve as secondary structural framing members across key industries:
Pre-Engineered Buildings: Roof purlins and side wall girts.
Industrial Warehouses & Workshops: High-load span support structures.
Solar Mounting Systems: Heavy-duty structural support tracks.
Commercial & Agricultural Buildings: Large-span secondary framing.
Core System Components
Reinforced Frame and Base
Rigid, stress-relieved steel frame designed to eliminate structural flex during continuous 4.0 mm forming passes.
High-Load Shafts and Tooling
Shafts engineered from forged 40Cr alloy steel, precision ground to hold tight tolerances. Rollers are CNC-machined from high-grade Cr12 / D2 die steel, heat-treated to HRC 58-62 for maximum wear resistance against thick galvanized stock.
Springback and Profile Control
Specially engineered roller profiles and side-thrust rollers eliminate material springback and profile twisting when processing high-yield structural steel up to G550/Q355.
Size Changeover Flexibility
Available with traditional spacer-based setup for dedicated high-volume sizes, or an automated PLC-driven width/flange quick-change system to reduce downtime between production runs.
Production Line Workflow
Decoiling and Loading: Heavy-duty expansion mandrel uncoils the raw material (optional coil car available).
Precision Leveling: Multi-roll leveler flattens coil set and stress-relieves strip prior to forming.
Entry Guiding: Adjustable guide rolls keep the strip aligned with the centerline.
Progressive Roll Forming: Multi-stand tool set gradually forms web, flange, and lip dimensions without stress-cracking the steel zinc coating.
Inline Hole Punching: Single or multi-group hydraulic/servo units punch connection holes in web and flanges according to programmed coordinates.
Cut-to-Length: Post-forming shear yields clean profiles without burrs or section distortion.
Discharge and Stacking: Run-out table or automatic stacking system collects finished purlins.
Punching and Cutting Options
Hole Configurations: Round, slotted, elongated, flange, and web hole groups.
Hydraulic Punching: Delivers high tonnage required for thick-gauge punching; ideal for standard hole patterns.
Servo Punching: High-speed, independent servo positioning for precise hole-to-hole tolerances and dynamic hole pattern changes.
Flying Shear: Performs non-stop cutting during continuous line travel to maximize output speed.
Factory Acceptance Testing
Every machine undergoes complete line assembly and material testing under real production loads prior to delivery:
Mechanical and Electrical Inspection: Component alignment, drive continuity, and safety circuit testing.
Software Calibration: PLC/encoder positioning, touchscreen HMI diagnostics, and multi-language verification.
Full-Load Forming Trial: Raw material running test using client-specified profile dimensions, steel grades, and thickness.
Profile Verification: Inspection of web width, flange height, lip angle, hole pitch accuracy, and finished section straightness against the approved profile drawing.
Frequently Asked Questions
Q: What maximum steel thickness and yield strength can this machine process?
A: The standard heavy-gauge configuration handles 2.0–4.0 mm thickness up to S350GD / Q355 steel. Higher strength grades (S550GD) can be processed by adjusting roller pass design and increasing main drive power.
Q: How long does it take to change between different Z purlin sizes?
A: With the fully automatic motorized PLC system, web width and flange height changeovers take under 10 minutes directly via the touchscreen HMI.
Q: Can the machine be custom-built according to our existing profile drawing?
A: Yes. All roller tooling layouts, punch dies, and cutter profiles are engineered specifically to match your CAD profile drawing and hole pattern requirements.
Q: Does the machine meet international electrical and safety standards?
A: Yes. Key components are sourced from global brands. The line is CE certified and wired to match your local power supply (380V–480V, 50/60Hz).
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