Roll-forming machine RF25

The roll-forming machine RF25 is used to produce grooves on rotationally symmetric components.

  • Ø 3 – Ø 25 mm rollable
  • up to Ø 1 mm wall thickness machinable
  • repeat accuracy ±0.05 mm
  • moulding cycle approx. 3-10 sec.

Chuck available with integrated stopper.

Attainable tightness of up to IP65 possible depending on material combination.

Freely programmable data base.

Unit adjustable to customer’s requirements.

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Machine setup

The roll-forming machine RF25CNC represents a consistent enhancement of existing systems for the grooving of pipes, pipe ends, sleeves, shells, armatures and many other applications.

When grooving a work piece, the machine can be programmed for up to three rolling positions per roll-forming process. 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 or tightening of protective cases.

The handling of the machine is very simple. The work piece is inserted into the opening, usually positioned with the help of a die grinder, which assures that it does not move while the tools roll around the axis of the work piece. 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.

Other applications in the field of cutting by chipless isolation of pipes are also possible. Producers of thermal elements use this roll-forming machine to remove end pieces from sheathed cables.

The basic machine is also used for rotary swaging, see RK25CNC.

Basic machine

  • basic module with fastening holes for the reception of all functional components consists of:
  • main base plate with vertical assembly block
  • drive system: 2 servomotors with toothed belt discs/toothed belt (2 CNC axes)
  • recirculating ball screw with screw nut and double thrust bearings, adaption to shaft guide of cone ring for infeed of tools
  • main ball screw mounted free of play by means of spring system for reception of tool holding disc
  • includes protection cover with gas spring, handle and security sensor

 

  • roll-forming head available in 2 versions:
    • option 1: 3 roll holders with product specific rollers
    • option 2: 1 roll holder with product specific rollers and 1 counter roll holder with counter roller
  • servo drive enables exact control of driving parts

 

Protection measures

  • protection door at front of forming head; easy insertion of parts guaranteed
  • front protection also available with light grid
  • includes protection cover with gas spring, handle and security sensor
  • emergency stop immediately stops all movements

 

Control system

  • VIPA Speed7 SPS with user panel Siemens TP700 comfort
  • parameterisation and user software installed
  • process parameter for all three grooves per data set can be freely parameterised
  • control cabinet installed into frame
  • additional buttons for start, stop and emergency stop
  • pedal button for release of forming process by operator
  • data sets selectable via user panel (by means of bar code scanner if desired)

 

Software

  • data display on user interface
  • calibration instructions are set up and selectable at all times via button
  • standard databank for product specific parameter with 50 data sets (expandable up to 4,000)
  • 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)

 

Frame

  • holds all machine components
  • standing work station, length x width x depth approx. 1,010 x 1,010 x 890 mm
  • working height approx.. 1,123 mm
  • 4 rotatable wheels, 2 with locking brake
  • welded and coated steel frame, colour can be chosen as requested
  • desk top made of steel or wood

Optional components – additions

The standard RollierFormer RF25 can be equipped with various optional attachments and functions. This makes it possible, for example, to expand the machine into a semi-automatic roller burnishing machine with process monitoring.

Models - RF25

  • roll-forming tool is opened; chuck in position for insertion and roll-forming
  • component part is inserted manually into chuck
  • position of component part is registered by sensor, chucks close
  • close protective door or take hands out of light grid
  • rollers roll around work piece, close and open
  • 1 rolling position possible
  • chucks open automatically
  • component part can be taken out of machine
  • moulding time depending on diameter 4 sec.

Height adjustable frame

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

Light curtain

  • Safeguards free access for equipping the SegmentFormer
  • With obstacle detection
  • Initial acceptance carried out

Nonstandard models

  • machine can be adjusted according to requirements
  • integration of machine into entire machine complex
  • cutting-off of component parts with circular knives (replace roll-forming rollers)
  • further alternatives possible

Technical data

Machine documents

Documentation

  • user and maintenance manuals
  • lists of parts, spare parts and working parts
  • electric diagram
  • specimens: 1 x paper, 1 x CD; language: German or English
  • production drawings of parts and source codes of software are not included
  • transfer of documentation after starting of machine

 

Hazard analysis, CE mark

  • hazard analysis is carried out and documented
  • machine / unit delivered with CE mark

Abmessungen Standard 1.000 x 1.000 x 1.400 mm (LxBxH)
Werkzeugdaten Anzahl Rollierrollen 1 / 3
Rollierrollen Gehärtet
Mögliche Rollierdurchmesser 3 – 25 mm
Max. Rillenbreite Bis 5 mm
Mögliche Wandstärken 0,2 – 2 mm
Spannungsversorgung Netz 3 x L / PE 400V / 50Hz
Leistung 3 kVA
Strom 8,2 A
Vorsicherung Max. 16 A
Leistungsquerschnitt 5 x 2,5mm²
Druckluft Nicht erforderlich
Gewicht Ca. 350 kg
Wiederholgenauigkeit ±0,05mm
Taktzeit Ca. 4 – 6 Sek. Je nach Durchmesser und Rillenzahl