••••••> Roll Forming for Roofing Components
Author: Lousie Smith Roll forming of roofing components for the preengineered building and component industries presents unique challenges for manufacturers. Tighter profile tolerances, wider product ranges, and compressed lead times present production challenges for producers running older equipment or those contemplating a move into this market. Some developments in equipment and processes that are important to producing secondary structural members include quickchange roll form tooling systems and tooling that can improve the productivity of roofing components Cee's, Zee's, Eave Struts, Channel, and Base Angle. Roll forming roofing components for the preengineered building and component industries presents unique challenges for fabricators. Tighter profile tolerances, wider product ranges, and compressed leadtimes are production challenges for producers running older equipment or those contemplating a move into this market. Coil Handling: The first step in improving roll formed roof framing components starts is coil handling equipment. Keeping the production line fed always has been a process that has a major impact on line productivity, and it is even more important today with the introduction of highspeed punching systems and quickchange roll formers. Reduced leadtimes and justintime (JIT) manufacturing philosophies have increased the number of daily coil changes, in some cases by tenfold. Running a complete coil is no longer the norm. Many producers are running a few parts and then switching to another coil, because they are increasingly producing complete buildings to order rather than rolling components to stock.
Many types of coil handling systems are available to help manage the process and improve productivity in this area. Coil storage racks, rotating turnstiles, and coil cars help production personnel stage coils into and away from the production areas. Coil management software is available to help streamline the flow of orders into manageable units that help the operator balance flexibility and productivity; knowing which coil is going to be run next (and the available length of that coil) is just as important as changing coils quickly.
Doublearm uncoilers with powered holddown rolls allow the operator to prepare the new coil
for production while the line is running and secure the partially used coil for offline rebanding, increasing line uptime. Automatic and semiautomatic feedup systems with band breakers and nose benders reduce the time required to get a new coil into production. Roll Forming: Today's roofing component producers need the ability to change from C to Z to single or doubleslopeeave struts, in a variety of sizes and gauges, all within the confines of a single order. Some new purlin production systems on the market today offer this flexibility with both automatic and semiautomatic changeover. Eave struts can be produced inline in either single or doubleslope configurations, eliminating an offline bending operation. Positive gauge changes can be manual or automatic, or in some cases accommodated with floating tooling. Eave struts can be produced inline in either single or doubleslope configurations, eliminating an offline bending operation. Positive gauge changes can be manual or automatic, or in some cases accommodated with floating tooling. Material Handling:
It may sound basic, but a highspeed purlin production system requires a highspeed material handling system, and a system capable of producing a range of parts requires a material handling system that can handle the full product range. Controls: Keeping pace with the change in forming technology, line controls have evolved as well. Machine controls are available with openarchitecture operating systems, enabling direct communication with a variety of production control systems. Many of these systems use offtheshelf components for local serviceability. For more information visit : http://www.internationalrollforms.com/