Roll-forming machine RF25

The roller-burnishing machine RF25 – roll-forming machine - is used for:

  • roll-forming of shells with cables or sleeves
  • roll-forming of cases with plugs
  • roll-forming of sleeves and pipes
  • roll-forming of sensors with cables

The roll-forming machine guarantees a form-fit connection which helps achieve, among other things, better strain-relief or tightness. 

For workers of rotationally symmetric components the roll-forming machine RF25 represents a consistent enhancement of existing systems for the roll-forming of pipes, pipe ends, sleeves, shells, armatures and many other applications.

A typical example is the implementation of sensor sleeves which mechanically protect connection leads from being pulled out and seal them at the same time (IP67 possible). This procedure also allows rolling of plugs into sensor sleeves and many more. Wall thicknesses of 0.2 mm up to approx. 2.0 mm with a diameter of 3 – 25 mm are possible.

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Machine setup

The handling of the roll-forming machine is very simple. The work piece is inserted into the opening, usually positioned with the help of a die grinder. A big advantage compared to other systems is that the work piece does not move while the tools roll around its axis. The corresponding working parameters can be stored and managed in the machine control system. The user interface allows easy and logical operation. All essential processes are electronically monitored and the data is stored in the control system. This ensures high process safety and reproducibility.

Basic machine

  • basic module for the reception of all functional components consists of: main base plate with carrier for 2 servomotors, recirculating ball screw and main ball screw
  • roll-forming head available in 2 versions:
  • option 1: 3 roll holders with product specific rollers. W > 0.5mm, Ø > 8mm
  • option 2: 1 roll holder with product specific rollers and 1 counter roll holder with counter roller. W < 0.5mm, Ø < 8mm

Protection measures

  • protection door at front of forming head; easy insertion of parts guaranteed
  • front protection also available with light grid
  • servo drive protected by protection cover and security sensor
  • emergency stop immediately stops all movements

Control system / Software

  • Siemens S7 CPU with user panel Siemens TP700 comfort; S7 and TIA portal V13
  • data sets selectable via user panel (by means of bar code scanner if desired)
  • data bank for product specific parameters
  • 3 access levels for machine control (user, service and administrator)
  • language can be chosen as requested (default German and English, other languages with extra charge)
  • control cabinet installed into frame


  • holds all machine components
  • welded and coated steel frame with 4 rotatable wheels, 2 with locking brake
  • aluminium section optional

Machine documents

  • documentation, hazard analysis, CE mark

Optional components – additions

The standard roll-forming machine RF25 can be equipped with different optional additions and functions to upgrade it, for example, to a semiautomatic roller-burnishing machine with process monitoring.

Models – RF25

  • manually with longitudinal slide to admit straining module. Driven by crank and trapezoidal thread spindle. Positioning with help of counting module.
  • standard chuck is used for straining of work piece
  • chuck geometry can be adjusted to work piece

Height adjustable frame

  • desktop mounted on height adjustable legs
  • height adjustable up to 300 mm
  • 4 rotatable wheels, 2 with locking brake

Light curtain

  • protection of free access for loading of roll-forming machine
  • obstacle recognition
  • initial inspection

Nonstandard models

  • machine can be adjusted according to requirements
  • integration of machine into entire machine complex possible
  • further alternatives possible

Measurements Standard 1.000 x 1.000 x 1.400 mm (length x width x height)
Die data number of roll-forming roller 1 / 3
Roll-forming rollers hardened
possible roller diameter 3 – 25 mm
max. groove widt up to 5 mm
possible wall thickness 0,2 – 2 mm
Power supply net 3 x L / PE 400V / 50Hz
Output 3 kVA
Current 8,2 A
Pre-fuse max. 16 A
Cable cross section 5 x 2,5mm²
Compressed air not required
Weight Ca. 350 kg
Repeat accuracy ±0,05mm
Cycle time ca. 4 – 6 sec. depending on diameter and number of grooves