I. Structure and Components
1. Main Structure
Double-layer Roll Forming Unit**: Consists of two independent upper and lower roller sets, each containing multiple precisely arranged forming rollers. These can simultaneously process two materials with different cross-sectional shapes or handle the same material in stages.
Frame: High-strength steel structure ensures stability during high-speed operation.
Adjustment Mechanism**: Manual or automatic roller spacing adjustment to accommodate material thickness and precision requirements.
2. Transmission System
Driven by servo motors or frequency-conversion motors, synchronized via gearboxes or chain drives for smooth material feeding without deviation.
3. Control System
Integrated PLC (Programmable Logic Controller) or CNC (Computer Numerical Control) systems for parameterized settings (speed, pressure, roller position). Some models feature touchscreen HMIs for easy operation and monitoring.
4. Auxiliary Devices
- Automatic feeders, levelers (for material preprocessing), cutting units (to trim finished products), and scrap recycling systems.
II. Working Principle
1. Material Preprocessing: Metal coils are uncoiled and leveled by a leveler to remove internal stress.
2. Double-layer Forming Process:
Upper and lower roller sets progressively bend the material through multiple passes to achieve the desired cross-sectional shape (e.g., corrugated, U-channel, C-channel).
The dual-layer design enables simultaneous production of two products or multi-stage forming for complex profiles.
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