रोल फॉर्मिंग लाइन

Linia CZUS Zeman

The line is from 2010. We have scheduled a modernization for 2021.

ZEMAN CZS LINE – SPECIFICATIONS

The fully automatic “PURLIN” line, ZEMAN’s flagship product, is designed for the manufacturing of open, cold-formed profiles such as C-, Z-, and Sigma-profiles in various widths and shapes. This is achieved by fully automated adjustment of the profiling rollers. The system can process coils up to 750 mm in width and sheet metal from 1.25 mm to 3 mm thick in steel grades up to S-390. The machine is configured to produce components up to 15 meters in length. The width of the specially hardened profiling rollers can be continuously adjusted via dedicated software. A fully integrated punching unit produces all types of fastening holes. The entire process runs continuously, meaning the material does not stop for individual operations such as punching or cross-cutting. For maximum production efficiency, line speed is dynamically optimized; the machine accelerates and decelerates automatically without operator intervention.

A decoiler with a maximum working load of 15 tons is mounted on a carriage, allowing precise centering of the strip before feeding into the straightener.

The straightening machine, in conjunction with a curvature correction system, ensures proper leveling of the material, maintains sheet flatness, and reduces bowing on the conveyor.

2. Punching Area
This section features five double “flying” punching portals which can be equipped with 20 small (up to 40 mm) or 10 large (up to 100 mm) tools (punches and dies) for punching fastening holes.

A combination of these tools is also possible.

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3. Pre-Cutting Shear
A “flying” shear is used for pre-cutting holes for the subsequent cutting shear. This ensures continuity of the material and results in more precise profiles, particularly at the start and end. It is an adaptive guillotine that automatically matches the width of the pre-cut hole to the sheet.

4. Guide Carriage/SIGMA Modules
The guide carriage centers the sheet before entering the roll former. It is interchangeable with the Sigma profile module. For producing S+ profiles, the guide carriage is removed and two Sigma modules are used. These modules automatically and independently position themselves left and right.

6. Rotary Cut-Off Saw
The rotary cut-off saw with hooked blades separates the completed profile from the strip. It makes use of the holes pre-cut by the previous shear. This is a “flying” cut-off saw, so the sheet does not stop during cutting. A specific cutting cassette, aligned with the desired profile, is used as required.

7. Outfeed Table
The outfeed table is designed for the automatic discharge of finished profiles from the roller conveyor. The elements are then manually bundled into a pack. The design allows easy bundling. The table is sized for profiles up to 15 meters and allows access by forklift or overhead crane to pick up the bundle.

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