Solar Panel Frame Roll Forming Machine (Carbon Steel Type)

Solar Panel Frame Roll Forming Machine (Carbon Steel Type)

1. Introduction

This roll forming line is engineered for manufacturing carbon steel frames used in photovoltaic (PV) solar panels. Designed for stability and efficiency, the machine automates punching, forming, and cutting in a continuous process, allowing for high-precision frame production with minimal material waste.

This model is optimized for long-run production with programmable control and real-time diagnostics.

2. Machine Composition

The system is composed of the following modules:

1. Manual Decoiler or Hydraulic Uncoiler

2. Feeding and Leveling System

3. Precision Servo Punching Station

4. Main Roll Forming Section

5. Servo Flying Shear Cut-Off Unit

6. Runout Table and Optional Auto Stacker

7. Centralized Electrical Control System (PLC + HMI)

8. 

3. Technical Data

Parameter	Specification
Frame Material	Cold rolled carbon steel, galvanized steel
Material Width	45 – 100 mm
Material Thickness	0.8 – 2.0 mm
Production Speed	Up to 15 meters per minute
Forming Stations	14 – 20 steps (customizable)
Cutting Tolerance	±0.3 mm
Punching Accuracy	±0.5 mm
Control System	Siemens PLC, touch HMI, encoder feedback
Required Power Supply	380V, 50Hz, 3-phase

4. Operating Procedure

▶️ Before You Start

• Check power connection, oil level in hydraulic system, and air pressure.

• Ensure the punching mold and cutting blade are clean and firmly secured.

• Load the steel coil on the uncoiler and lock with safety clamps.

▶️ Startup Process

1. System Boot

   • Switch on the main power.

   • Wait for the control panel to complete system diagnostics.

2. Parameter Input via HMI

   • Input length of frame, punching positions, and number of holes.

   • Set the batch quantity and material thickness.

   • Load or recall saved profile data if applicable.

3. Material Feeding

   • Jog feed the material to align with the punching station.

   • Use the “manual run” mode to test one cycle before full run.

4. Production Mode

   • Switch to “Auto Run”.

   • Monitor the HMI screen for live speed, punch counts, and cut count.

   • Inspect first 2–3 frames for dimensional accuracy.

▶️ Stopping & Changeover

• Press “Stop” and wait for the current piece to finish cutting.

• Change punching dies or adjust rollers if switching frame types.

• Use jog mode to test feed before resuming auto production.

5. Routine Maintenance

6. Troubleshooting Guide

7. Frequently Asked Questions (FAQ)

Q: Is carbon steel strong enough for outdoor frames?
A: Yes. With proper galvanization or powder coating, carbon steel frames offer excellent strength and corrosion resistance at a much lower cost than aluminum.

Q: Can one machine make different sizes?
A: Absolutely. Frame length, hole positions, and even roll gaps can be adjusted via PLC. Some wider profiles may need partial tool change.

Q: What is the estimated tool life?
A: Punching dies typically last 80,000–120,000 cycles depending on material. Cutting blades may last 30,000–50,000 cuts with proper lubrication.

Q: Can I integrate a stacker later?
A: Yes. The output section includes optional ports and logic for integration with auto stackers or robotic arms.

8. Safety Instructions

• Never place hands near the roll station during operation.

• Always disconnect power before adjusting tooling.

• Emergency stops are located at the entry and exit ends.

• Wear gloves and safety glasses when changing dies.