Three Layer Roll Forming Machine

1. Product Overview

Three Layer Roll Forming Machine is an integrated multi-functional cold roll forming equipment designed for metal building material production. It combines three sets of independent roll forming systems on one single machine base, enabling one equipment to manufacture three different types of metal roof panels and wall sheets. This three-in-one design effectively saves workshop space and reduces repeated equipment investment, compared with purchasing three separate single-layer machines. The machine can process color coated steel, galvanized steel and aluminum coils into standard building steel panels through automatic decoiling, leveling, continuous roll forming and fixed-length cutting. It is an ideal solution for manufacturers with diversified tile profile demands, widely used in building material factories and steel structure engineering projects worldwide.

2. Production Process Flow

Hydraulic Uncoiling → Material Leveling & Guiding → Three-layer Selective Feeding → Multi-station Roll Forming → Hydraulic Flying Cutting → Finished Sheet Output

Optional accessories: pre-punching device, embossing device and automatic stacking system according to customer requirements.

3. Main Technical Parameters

This three-layer forming machine is suitable for raw material thickness from 0.3mm to 0.8mm, compatible with color steel, galvanized steel and aluminum coils. It supports standard coil inner diameter of 508mm, with maximum coil loading weight of 3 to 5 tons. Three independent roller groups are arranged in upper, middle and lower layers, configured with sufficient forming stations to ensure precise shaping for different profiles without deformation or scratches.

The whole line adopts gearbox drive for stable and low-noise operation, with working speed ranging from 8 to 16 meters per minute. Equipped with high-precision encoder length measurement system, the cutting tolerance is controlled within ±1mm. The machine adopts PLC and HMI touch screen control, supporting one-key switching of three different production modes. Standard voltage is 380V/50Hz 3-phase power, which can be customized to fit local power standards of different countries.

4. Machine Structure & Components

4.1 Hydraulic Uncoiler

Equipped with 3–5 tons hydraulic automatic uncoiler, featuring auto expanding and tension brake function. It keeps steel coils stable during continuous feeding, effectively preventing material deviation, coil loosening and feeding jamming, ensuring stable material supply for long-time running.

4.2 Three Layer Forming Host

The main frame is constructed with heavy-duty welded steel and stress-relief treatment, ensuring no deformation under long-term high-load operation. All forming rollers are made of GCr15 alloy steel with high-frequency quenching and hard chrome plating, featuring high hardness, wear resistance and long service life. Three sets of forming systems work independently without mutual interference. Operators can switch three different tile profiles quickly through the control panel without replacing rollers, greatly improving production flexibility.

4.3 Hydraulic Cutting Unit

The cutting blade adopts Cr12MoV mold steel with integral quenching treatment. Adopting flying cut structure, the machine can finish fixed-length cutting in continuous running status without shutdown, which improves production efficiency and guarantees smooth and neat sheet cutting surface.

4.4 PLC Intelligent Control System

The system consists of PLC controller, touch screen and frequency converter. All parameters such as sheet length, production quantity and layer switching can be set on the touch screen. It supports fully automatic running, real-time data display and automatic fault alarm, making operation simple and maintenance convenient.

4.5 Output Platform

The specially designed multi-layer output rack matches three different finished panels. It supports manual collection and can be equipped with an automatic stacker to reduce labor cost and improve overall automation level.

5. Core Advantages

Three-in-One Multi-function: One machine produces three different roof and wall panels, replacing three single-layer machines. It greatly saves workshop area and reduces customer’s equipment purchase cost.

Flexible & Fast Switching: Independent three-layer design supports one-key profile switching. No need to change rollers or adjust frames frequently, which improves production efficiency and meets diverse order demands.

Stable Forming & High Precision: Gearbox transmission and professional roller profile design ensure flat sheet surface, uniform size and high forming precision, fully meeting construction installation standards.

Low Labor & High Efficiency: High automatic operation allows one worker to run the whole production line. Non-stop flying cutting realizes continuous mass production.

Durable & Low Maintenance: All core parts undergo strict heat treatment, with stable performance and low failure rate, supporting long-term continuous operation.

Customizable Profiles: We can design and manufacture roller molds according to customers’ drawings to match local popular roof and wall panel specifications.

6. Application Scope

The three layer roll forming machine is widely used for producing various building color steel panels, including trapezoidal roof sheets, corrugated wall sheets and glazed tiles. Finished panels are suitable for steel structure workshops, warehouses, prefab houses, villas, farm sheds and various industrial and civil building enclosure systems.