Door Frame Roll Forming Machine

1. Decoiling --- motorized decoiler with pneumatic expanding mandrel (capacity 3-ton or 5-ton) uncoils pre-painted galvanized or cold-rolled steel strip, feeding through an entry guide with ceramic-coated side rollers to prevent edge damage to the paint finish.
2. Leveling --- nine-roller precision leveler removes coil memory and delivers flat strip to the forming section; leveler roller pressure is dial-adjusted per material gauge to avoid overworking the pre-painted surface.
3. Multi-cavity roll forming --- 16 to 22 progressive forming stations bend the strip into the specified door frame profile; each station pair is mounted in a cassette frame, and cavity type is changed by swapping cassette sets (single-cavity cassette → double-cavity cassette) using the overhead gantry hook included in the line layout.
4. Hinge hole punching --- two to four hydraulic punch units positioned at preset distances punch hinge mounting holes into the formed profile; punch depth is micrometer-adjustable, and the punch sequence is triggered by encoder count from the forming drive, ensuring hole position accuracy regardless of line speed.
5. Lock slot cutting --- a dedicated hydraulic notching station cuts the lock mortise opening (rectangular slot or circular hole) into the frame profile at the encoder-triggered position; the punch-die set is sized to the lock brand specification.
6. Length cutoff --- servo-driven flying cutoff shear moves with the profile during the cut stroke, producing a square cut face perpendicular to the profile axis; blade clearance is adjustable for gauge range 0.8--2.0mm.
7. Collection and bundling --- formed frame sections slide onto a run-out table with side-aligning pneumatic clamps; an operator stacks cut lengths into bundles of 10 or 20, which are then strapped and transferred to the assembly or painting line.

Quality control for door frame profiles emphasizes dimensional accuracy at the corner joints and surface finish preservation, because door frames are visible finished surfaces and any defect at the welded corner adds rework cost and delays downstream assembly.

• Frame corner squareness verified by assembling two cut frame sections into a 90° corner on a welding fixture --- the diagonal measurement difference across opposite corners must not exceed 1.0mm on a 2.1m × 0.9m door frame.
• Hinge hole concentricity checked with a stepped gauge pin --- both holes (frame side and reinforcement plate side) must align within 0.3mm axial offset to ensure smooth hinge pin insertion during door assembly.
• Lock mortise depth measured with digital depth gauge --- the slot depth must match the lock body specification within ±0.3mm; a shallow slot prevents full lock seating, while an over-deep slot weakens the frame web at the lock position.
• Overall frame section dimensions checked against the approved profile drawing at the first-piece inspection and every 200 frames thereafter --- key checkpoints: cavity width, flange height, and return lip length, all within ±0.5mm of nominal.
• Surface coating integrity inspected under 1500-lux fluorescent lighting at a 45° viewing angle --- any scratch, scuff, or roller mark exceeding 3mm in length or penetrating the zinc layer triggers a roller surface inspection and possible polishing intervention.
• Weld seam consistency for frames using welded tube input --- seam position must be controlled by the strip entry guide to place the weld on the non-visible frame face; seam burst or undercut at the corner weld joint is a reject criterion.
• Bending radius at formed corners --- the minimum bend radius must not drop below 1.5× material thickness; tighter bends concentrate stress and produce micro-cracking in the zinc coating that leads to premature red rust at frame corners in service.

Door Frame Roll Forming Machines are mid-size roll forming lines with a total length typically between 6m and 10m, making them compatible with a standard 40-foot High Cube (40HQ) closed container --- a significant logistics advantage since general-purpose containers are more readily available and cheaper to ship than open-top alternatives. The machine is disassembled into two main modules: the decoiler-leveler section and the forming-punching-cutting section. Each forming roller cassette (single-cavity, double-cavity, or both, depending on the order) is packed in a dedicated plywood crate lined with VCI anti-corrosion paper and reinforced with steel edge protectors at all eight corners. The crates are internally partitioned with foam dividers so individual rollers do not contact each other during transit, eliminating the risk of roller surface bruising that would transfer marks onto pre-painted door frame surfaces.

All hinge hole punch tooling and lock slot punch-and-die sets are packed in labeled compartment boxes --- each box marked with the corresponding door brand or cavity profile designation (e.g., \"Hinge Punch --- 125mm CC --- Left Hand\" or \"Mortise Lock --- 16mm Euro Profile\") so that installation crews can locate and mount the correct tooling immediately during commissioning. The touchscreen HMI panel is removed from the control cabinet and packed in its original factory carton with foam inserts, then placed inside the control cabinet crate for consolidated shipping. The hydraulic power unit is drained of oil and the filler cap is replaced with a sealed shipping plug; the hose connections are capped with plastic dust plugs and bundled with releasable cable ties. Machine foundation bolts, leveling shims, and the overhead cassette-change gantry rail are packed in a separate hardware crate with a detailed inventory checklist that the receiving party uses to confirm completeness before signing the bill of lading.

Unionindus after-sales for Door Frame Roll Forming Machines prioritizes cavity changeover competence and fine-tuning of hinge/lock punching accuracy --- the two operational areas where door manufacturers lose the most production time during product changeovers.

• On-site commissioning over 4--6 working days by one mechanical commissioning engineer and one electrical/PLC engineer, covering assembly, roller cassette alignment, punch station calibration, and production of sample frames in each cavity configuration.
• Cavity changeover procedure training: operators complete two full cassette swaps (e.g., single-cavity to double-cavity and back) covering roller cassette lifting, rail-guided positioning, bolt-down torque sequence, and strip threading through the new roller path.
• Hinge hole punch adjustment training for different door brands --- the engineer demonstrates repositioning the hydraulic punch carriage on the linear rail, verifying center-to-center distance with a calibrated scale, and fine-tuning the punch stroke depth based on material gauge.
• Lock slot depth calibration using a master gauge block --- operators learn to check and adjust the notching station depth stop and to correlate depth measurement with lock body fit on assembled frame samples.
• Surface scratch troubleshooting guide for pre-painted coils --- covers roller surface inspection under magnification, identification of debris pickup points in the strip path, roller polishing frequency based on linear meters processed, and ceramic guide roller replacement intervals.
• PLC program backup and recipe storage --- the commissioning engineer saves all production recipes (punch positions, line speed, cutoff lengths per cavity type) to a USB drive and demonstrates recipe recall and parameter modification on the HMI.
• 12-month mechanical warranty and 24-month electrical/PLC warranty, with remote diagnostic access via industrial VPN router (supplied and configured during commissioning) for software troubleshooting and parameter adjustments without an on-site visit.
• Commissioning spares kit: two sets of lock slot punch-and-die inserts, two sets of hinge hole punch bushings and pins, one set of entry guide ceramic rollers, and one touchscreen protective film replacement --- all packed and labeled in the control cabinet at shipment.