This introduction details the roll forming machines commonly used in the US market for producing double-layer AG profile roof panels (typically metal composite panels or sandwich panels). Key note: "AG profile" in the US market usually refers to a specific steel grating or roof/wall panel profile defined or popularized by American Grating (AG). Its characteristics include high strength, excellent drainage performance, and aesthetics. When referring to "double-layer AG profile roof panels," it typically means panels using this profile as the outer skin, combined with an inner skin (usually flat or corrugated sheet) via a roll forming process, with insulating core material (such as Polyurethane PU, Polystyrene EPS, Rockwool RW) filled in between, forming a composite sandwich panel.
Therefore, the core equipment for producing such double-layer AG profile roof panels is a continuous metal composite panel / sandwich panel production line, and its central unit is the roll forming machine (more accurately, a dual-layer metal skin roll forming system).
Core Equipment: Dual-Layer Metal Skin Roll Forming System
The roll forming section of this production line essentially consists of **two independent roll forming machines working in coordination:
1. Outer AG Skin Roll Forming Machine:
Function:Forms coils of prepainted steel sheet (typically Galvalume or galvanized steel with PVDF or polyester coating) into the specific AG profile through a series of precisely designed roll stations.
AG Profile Characteristics:
High Ribs: Usually features high vertical ribs (60mm, 80mm, or even higher), providing exceptional structural strength and spanning capability.
Wide Coverage: Large effective coverage width (common 1000mm or 42 inches), reducing overlaps and improving installation efficiency.
Concealed Fastening: Designed to allow concealed fasteners (e.g., standing seam systems), resulting in a clean roof appearance and superior waterproofing.
Drainage Performance: Rib design optimizes rainwater runoff, reducing ponding risk.
Aesthetics: Features smooth, flowing rib lines with a modern look.
Roll Tooling: Consists of multiple passes (typically 12-24 or more) of precision-hardened alloy steel rolls. Each pair of rolls applies specific bending forces to the metal strip, progressively shaping it from flat stock into the final AG cross-section. The design and machining accuracy of the rolls directly determine the dimensional precision and surface quality of the final panel.
Drive: Powered by high-power AC or servo motors, ensuring stable and synchronized forming.
2. Inner Skin Roll Forming Machine:
Function: Roll forms another coil of metal strip (also typically Galvalume or galvanized steel, sometimes thinner gauge, potentially with lower coating requirements than the outer skin) into the required shape. The inner skin profile is relatively simpler, common types include:
Flat Sheet: The simplest form.
Small Corrugation: Adds stiffness and bonding surface area with the core.
Special Interlock Structure: Designed to interlock with the AG panel edges or bond more securely to the core material.
Roll Tooling: Fewer passes than the outer AG skin former (possibly 6-12 passes), with a relatively simpler structure.
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