The Comprehensive Guide to Roll Forming Machine Components and Pricing Factors

Introduction

1. Core Components of a Roll Forming Machine

1.1 Uncoiling & Pre-Processing System

• Uncoiler: Holds metal coils and controls unwinding via hydraulic or electric drives. Key types: cantilever (for small coils) and horizontal (heavy-duty).
• Leveler: Straightens coiled material using 5–11 sets of hardened steel rolls, eliminating waves and bends to ensure flatness within 0.5mm/m.
• Feeding System: Transfers material with precision. Servo feeding (±0.1mm accuracy) outperforms roller feeding in high-precision applications.

1.2 Forming & Processing System

• Punching Unit: Performs pre-forming holes or notches, ranging from single-punch to multi-station turret punches for complex patterns.
• Guide Device: Prevents material deviation with side and pressure rollers, ensuring consistent alignment.
• Main Forming Unit: The heart of the machine, featuring 8–15 sets of forming rolls in a housing:
  • Wall-type housing: Rigid, suitable for thick plates (≥3mm), higher cost.
  • Independent housing: Modular, ideal for thin plates (<2mm) and flexible production.
• Straightening Unit: Corrects post-forming distortions, achieving straightness of ±0.5mm/m via adjustable pressure rollers.

1.3 Post-Processing & Discharge System

• Cutting Device:
  • Flying shear: Cuts moving material at >50m/min (±0.5mm accuracy).
  • Stop shear: Cuts stationary material, cheaper but slower (<20m/min).
• Discharge Table: Collects finished profiles, from manual racks to automated stacking systems with conveyors.

1.4 Control & Auxiliary Systems

• Electrical Control: PLC (e.g., Siemens, Omron) + HMI, with servo systems for high-speed precision (response <0.1s).
• Hydraulic/Pneumatic Systems: Powers punches and cutters (10–20MPa hydraulic pressure) and controls guides (0.6–0.8MPa air pressure).

2. Key Factors Influencing Roll Forming Machine Prices

2.1 Equipment Specifications

• Material Parameters: Thickness (e.g., 5mm steel machine costs 3x more than 0.5mm), width (1200mm vs 500mm increases cost by 20–50%).
• Forming Speed: Low-speed (<10m/min) vs high-speed (>80m/min) lines, with the latter costing 5x more due to servo drives and flying shears.

2.2 Technical Configuration

• Drive System: Hard-tooth surface reducers (95% efficiency) cost 50% more than worm gears but offer better durability.
• Automation Level: Manual adjustment vs electric/hydraulic auto-adjustment (adds 50–100% to cost).
• Integrated Functions: Single forming machine vs fully automated lines (punching, cutting, stacking) cost 2–5x more.

2.3 Component Quality & Materials

• Housing & Rolls: Cast steel wall-type housing (40–60% pricier than cast iron), Cr12MoV rolls (30% costlier than 45# steel).
• Reducer Brands: Imported hard-tooth reducers (e.g., SEW) cost 30–80% more than domestic models.

2.4 Customization & Production Scale

• Non-Standard Designs: Special profiles require custom rolls, adding 15–30% to costs.
• Explosion-Proof/Corrosion Resistance: Special materials (stainless steel) for harsh environments increase costs by 20–40%.

2.5 Brand & After-Sales Service

• Imported vs Domestic Brands: German (Rasnick), Japanese (Amada) machines cost 2–4x more than Chinese brands.
• Warranty & Support: Extended warranties and local service networks may add 5–10% to the price but reduce long-term costs.

3. Typical Price Range (RMB)

4. Selection Tips for Cost Optimization

1. Match Specifications to Needs: Avoid over-specifying (e.g., heavy-duty machines for thin plates).
2. Prioritize Key Components: Invest in reliable reducers and servo systems for long-term efficiency.
3. Balance Customization: Evaluate if non-standard profiles justify mold development costs.
4. Localize Service: Choose suppliers with nearby support to minimize downtime.

Conclusion