Product Overview
The Purlin Roll Forming Machine with Flying Cut-Off delivers continuous, high-efficiency C and Z purlin production directly from steel coils. Designed for industrial-scale manufacturing, the system features dynamic in-line cutting: after reaching the programmed length, the flying cutter synchronizes with the moving purlin to complete precision cutting without stopping the forming line.
Key Specifications
|
Item |
Reference Specification |
|
Profile Type |
C / Z / C&Z Interchangeable / Customized Profile |
|
Web Width |
100–400 mm |
|
Flange Width |
40–100 mm |
|
Lip Height |
15–30 mm |
|
Material Thickness |
1.5–3.5 mm |
|
Applicable Material |
Galvanized Steel, Carbon Steel (GI, PPGI, HR/CR Coils) |
|
Material Yield Strength |
Up to ~550 MPa (subject to design and profile geometry) |
|
Line Speed |
20–40 m/min (continuous operation) |
|
Cutting Method |
Non-stop Flying Cut-Off (Hydraulic or Servo Drive) |
|
Length & Hole Control |
PLC + High-Precision Encoder Control |
|
Punching Integrated |
Optional (Hydraulic Punching Units) |
Key Advantages
High Productivity: Flying cut-off capability boosts output up to 40 m/min without line pauses.
Fast Profile Changeover: Transition between C and Z sections in 3–5 minutes, minimizing downtime between job orders.
Material Versatility: Smoothly processes heavy-gauge and high-tensile material up to 550 MPa without structural machine distortion.
Precision & Low Scrap: Advanced servo-encoder synchronization guarantees cut-length accuracy within ±1.0 mm or less and clean cut edges with minimal burr.
Reduced Labor Costs: Automated sizing, punching, cutting, and stacking options reduce operator count requirements to 1–2 technicians.
Industry Uses
This roll forming line is engineered for high-volume manufacturers producing structural framing members for:
Pre-Engineered Steel Buildings
Industrial Warehouses & Commercial Facilities
Solar Panel Mounting Structures
Agricultural Buildings & Sheds
Architectural Roof Truss and Wall Girt Systems
Purlin Profile Range
|
Profile Parameter |
Reference Range |
|
Web Width (W) |
100–400 mm |
|
Flange Width (F) |
40–100 mm |
|
Lip Height (L) |
15–30 mm |
|
Material Thickness (T) |
1.5–3.5 mm |
|
Finished Length |
Programmable (No maximum limit) |
|
Profile Options |
C Section, Z Section, or C/Z Interchangeable |
Roll Forming & Tooling Design
The forming section utilizes a calculated station-by-station progression to distribute material strain evenly, preventing profile twist, bow, or edge wave.
Roller Quality: Manufactured from high-grade alloy or tool steel, heat-treated for long wear life under high-yield material conditions.
Structural Rigidity: Heavy-duty shafting and reinforced stands maintain dimensional accuracy across varying gauge thicknesses.
Multi-Size Adaptability: Configurable with quick-change spacers or fully motorized adjustment mechanisms to cover the entire dimensional range efficiently.
Integrated Punching System
When structural mounting holes are required, an in-line punching station is integrated into the control loop.
Capabilities: Round holes, elongated slots, web/flange hole patterns, and repeating structural hole groups.
Accuracy: Punching sequences are fully synchronized with the length-tracking encoder to ensure pitch and edge distances conform strictly to your profile drawings.
Automation & Control
The line features a central PLC control platform with an intuitive touchscreen interface for complete production management.
Recipe Storage: Save and recall dimensional presets, hole patterns, length batches, and speed profiles for fast setup.
Automated Size Change: Available motorized adjustment controls allow operators to switch profile widths and flange dimensions directly from the screen, minimizing manual tool adjustments.
C/Z Changeover: Integrated rotation or flip mechanisms enable swift transition between C and Z profiles on the same line.
Factory Acceptance Testing
Before shipment, every machine undergoes rigorous dry and load testing at our facility:
Frame & Shaft Alignment: Laser-checked concentricity and parallel alignment across all forming stations.
Trial Production: Sample purlin runs using customer-specified coil material.
Tolerance Verification: Full dimensional check of finished C/Z purlins including web/flange dimensions, hole spacing, profile straightness, and cut length.
System Diagnostics: Thermal imaging of gearboxes/motors and full automation stress tests.
Frequently Asked Questions
Q: What is the main advantage of a flying cut-off over a standard hydraulic cut-off?
A: A standard cut-off requires the entire forming line to stop for every cut, limiting line speed and causing mechanical wear. The flying cut-off cuts while the material continues moving at full speed, increasing total line output by 35%–50%.
Q: How long does it take to switch production from C purlin to Z purlin?
A: With our automatic changeover system, switching between C and Z profiles takes approximately 3–5 minutes directly via the PLC touchscreen.
Q: Can one machine handle different web and flange sizes?
A: Yes. The machine features step-less width adjustment. Web width (100–400 mm) and flange height (40–100 mm) can be adjusted automatically through the control system.
Q: What is the service life of the forming rollers and cutting blades?
A: Rollers made of vacuum heat-treated Cr12/D2 steel (HRC 58–62) with hard chrome plating typically achieve a service life of 10+ years under normal maintenance.
Q: How do you support overseas installation and commissioning?
A: We provide complete technical documentation, foundation layouts, and operation manuals. We offer remote online commissioning via video support as well as dispatching field engineers for on-site installation, line tuning, and operator training upon request.
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