Common Problems with Rollforming Machines - Part 4

By New Tech Machinery.

Learn more about panel markings and how to prevent them.

The previous three parts of this article went into detail about oil canning, panel curvature, and shear misalignment.  These problems are defined and steps are provided to help remedy the issues. In part four of this article, we explain the other most common problem that can occur with rollforming machines, which is panel markings.  

Problem #4 - Panel markings

What are Panel Markings?

Panel markings are pretty self-explanatory, meaning they are marks on the panel that occur during the rollforming process.  These might take the form of long streaks or imperfect spots on top or bottom of the panels. Additionally, what appears just to be panel markings might also be scratches that are stripping the paint off of the metal substrate.

Why Do Panel Markings Happen?

For the most part, panel markings are due to dirt and debris stuck in or on one of the components inside of the rollformer.  Some common causes of markings include:

• Dirt and debris trapped in the forming or drive rollers

• Film on the metal sheet/coil catch a roller or get stuck in the machine

• Pieces of plastic getting caught up in the machine

• The metal is scraping up against the exit or entry shera dies

How to Prevent or Fix Panel Markings

Since panel markings have so many different underlying causes and origins, there are a variety of fixes and recommendations for remedying the problem.

If a part of the machine is out of alignment and scratching the paint off of the metal, it’s imperative to try to pinpoint the issue so you can reference the manual for how to fix it.

For other issues where there is something stuck in the machine, we recommend the following to prevent or fix the problem:

• Before operating the machine, always visually inspect for foreign objects, debris, film, or anything unusual present within the machine.  If something doesn’t seem right, check and remedy the problem before running any roof panels.

• Keep the machine empty during transportation and when in storage.

• Avoid storage of the machine outdoors for long periods.  If possible, cover the machine with a tarp to protect it, but still provide proper ventilation to prevent condensation and rust from forming.

• Always keep the machine covers on during operation and storage.  The covers are for operator safety, but also protects the internal components of the machine from the environment.

• Regularly clean drive rollers with soap and water and a Scotch Brite Pad.  (CAUTION: Do not use harsh chemicals or solvents or damage will occur.)

Final Thoughts

One of the easiest ways to prevent an issue before it happens is staying educated on potential problems and knowing what to look for before it turns into a significant issue.

To recap:

• Oil canning is an inherent characteristic of flat fold-rolled metal.  One of the best ways to prevent it from occurring is to put rigidity, such as a rib roller or striations, into the flat section of the panel.

• Uphill or downhill panel curvature can be fixed with adjustments in the camber station.

• Shear misalignments are frequently due to profile changes and can be remedied by adjusting the entry and exit shear dies or the blades.

• Proper maintenance and care when the portable roof panel machine is in and out of use will help ensure the panels are not marked up during rollforming.

Learn more about New Tech Machinery.  

Source: New Tech Machinery