C/Z Purlin Roll Forming Machine

1. Decoiling --- 5-ton or 8-ton hydraulic decoiler feeds galvanized steel coil (GI or pre-painted) through a flattening-leveling unit that corrects coil set and delivers flat strip to the forming section.
2. Leveling and guiding --- seven-roller leveler removes longitudinal curvature; side-guide rollers align strip to centerline within 0.3mm lateral deviation before entering the punch station.
3. Pre-punching --- four to six hydraulic punch units create bolt connection holes (flange holes, web holes, lip stiffener holes) according to the programmed purlin-hole pattern; punch alignment is PLC-synchronized with encoder feedback from the forming drive.
4. Roll forming --- 16 to 20 progressive forming stands gradually bend the flat strip into the target C or Z cross-section; each stand uses heat-treated Cr12MoV rollers ground to the specific profile geometry.
5. C/Z conversion and size adjustment --- gear motor drives the spacer mechanism to adjust web depth; C-to-Z profile change is executed by rotating each forming station base 180° on its mounting bed, governed by a common drive shaft for synchronized rotation.
6. Length measuring --- encoder wheel tracks material feed and signals the cutting system at the preset purlin length (accuracy ±1mm over 12m).
7. Hydraulic cutting --- stationary or servo flying cutoff shear cuts the formed purlin at the measured length; the blade profile matches the C or Z cross-section to produce a clean cut without lip deformation.
8. Automatic stacking --- purlins discharge onto a run-out table and are collected by a multi-arm pneumatic stacker, forming level bundles ready for strapping and warehousing.

Quality assurance for C/Z purlin production targets dimensional accuracy and batch consistency because even minor deviations compound across structural assemblies where purlins are bolted to rigid frames at 1.2--1.5m spacings.

• C-section width after forming measured at three points along a 6m sample --- tolerance ±1.0mm on web depth and ±0.8mm on flange width from the first to last stand.
• Z-section lip angle verified with digital protractor --- acceptable range is 45°±1.5°; a lip angle deviation of 2° or more causes misalignment at purlin-lap joints during site erection.
• Bolt hole position tolerance checked using a go/no-go gauge fixture --- hole center position must fall within ±0.5mm of the programmed coordinate for all holes along a 6m purlin.
• Purlin straightness measured by placing the formed section on a granite surface plate --- camber and sweep must not exceed 1.5mm per 3m of length (L/2000 standard).
• Cutting-end deformation evaluated visually and with a profile template --- burr height under 0.3mm; flange pinch or web crush at the cut face is a reject criterion.
• Batch repeatability verified by sampling one purlin per 50 produced --- dimensional drift exceeding 0.5mm on web depth triggers intermediate size recalibration.
• Coating integrity of galvanized strip post-forming inspected under 1000-lux illumination --- zinc flaking or cracking at bend radii indicates excessive forming pressure or roller wear requiring immediate roller regrinding.

C/Z Purlin Roll Forming Machines are among the longest equipment in roll forming --- a typical line spans 12m to 18m depending on the number of forming stands and the stacker run-out table length. Standard delivery uses a 40-foot High Cube Open Top (40HQ OT) container with the machine partially disassembled into three or four sections: decoiler-leveler module, punch-forming module, cutting module, and stacker. Rollers on all forming stands are wrapped in anti-rust VCI (volatile corrosion inhibitor) film and then covered with polyethylene shrink wrap, with desiccant bags placed between roller gaps. Hydraulic oil is fully drained from the power unit tank, and the hydraulic cylinder rods are retracted and coated with lithium-based grease to prevent pitting during sea transit. The PLC control cabinet is vacuum-sealed in a moisture-barrier bag with silica gel indicators, and the touchscreen HMI is removed and packed separately in a custom foam-cut flight case.

All electrical cables are labeled at both ends with heat-shrink tube markers matching the wiring schematic, and cable connectors are capped with IP65-rated protective plugs. The main forming bed sections are bolted to steel pallets with M16 threaded rods through the machine base anchor holes, and heavy-duty ratchet straps secure the assembly against lateral movement. For destinations requiring inland trucking beyond the port, Unionindus provides a detailed lifting plan with center-of-gravity marks on each section, enabling safe offloading with a 10-ton mobile crane. Every crate exterior carries a weatherproof packing list pocket, and the full machine assembly manual, foundation drawings, and electrical schematics are shipped in a waterproof document tube attached to the control cabinet section.

Unionindus after-sales for C/Z Purlin Roll Forming Machines focuses on production ramp-up within the first 72 hours of commissioning, addressing the profile changeover and punching alignment challenges unique to dual-profile purlin lines.

• On-site commissioning for 5--7 working days by one mechanical engineer and one PLC programmer who assemble, level, and synchronize all modules to the operator\'s floor plan.
• C/Z conversion mechanism setup training: operators practice three full C-to-Z and Z-to-C changeover cycles under supervision, including spacer torque verification and rotation lock pin engagement sequence.
• Automatic size adjustment recipe programming: the PLC programmer creates and stores the operator\'s actual production recipes (e.g., C150×50×2.0, Z200×65×2.5) with all roller gap and punch coordinates saved for one-touch recall.
• Punching station alignment procedure: the commissioning team runs 10 test purlins of each size through full punching cycles, measuring hole positions with a calibrated fixture and adjusting punch rams until all positions meet the ±0.5mm tolerance.
• Roller change procedure documentation and hands-on demonstration for different profile depths --- covers roller removal sequence, bearing inspection, and regrinding frequency thresholds based on tonnes produced.
• PLC troubleshooting guide for size-change sequence faults --- includes sensor signal verification at each forming stand, encoder pulse count validation during size transitions, and manual override procedures for stuck stations.
• 12-month warranty on mechanical components and 24 months on the PLC and servo drive systems, with remote diagnostics via TeamViewer for software-related issues.
• Consumable spares kit included at shipment: two sets of cutoff blades, four hydraulic pump shaft seals, 50m of VCI anti-rust film for roller storage, and one spare encoder wheel with mounting hub.