A double layer roll forming machine, also known as a double layer forming machine, is a type of roll forming machine that is capable of producing two different forms of metal roofing or wall cladding sheets on one machine, which allows for the customization of the products depending on the customers personal need.
Both the double layer roll forming machine, which is the counterpart of the single layer roll forming machine, and the single layer unit have their own advantages and the disadvantages that differentiate these two types of roll forming machines, and thus make the customers choose one over another based on their preferences.
A forming machine is a device that fabricates the metal workpieces by shaping the required parts with the compressive force that the machine provides, which maximizes the rigidity and durability of the products compared to other manufacturing procedures.
The roll forming machine applies sets of rollers for the fabrication of the workpieces, and allows the workpieces to be pressed depending on the required geometries, which can be commonly seen in the manufacturing of the metal roofing or other products with similar shapes or forms.
Generally, the roll forming machines are designed with a single layer of rollers, which means that the shapes of the products that are made on these machines would follow that one and only row of the rollers. However, when the single form of the roller arrangement is not enough to accommodate the need of the customers, the manufacturers may prefer adopting several different forms of the single layer roll forming machines, one double row roll forming machine, or the double layer roll forming machine instead.
● Double layer of rollers
Despite the different names that the single and double layer roll forming machines have, the composition of a double layer roll forming machine is similar as the single form. A double layer roll forming machine consists of an uncoiler, a series of roller former, a cutter, a run-out table, a control box, and a hydraulic fluid pump.
The one most obvious difference between the single layer and the double layer roll forming machines is the two layers of rollers that the latter has, including the upper and lower layers, which allow for the production of different forms of the products respectively.
● One layer works at a time
However, the machine is able to work on only one layer at a time. The controlling of the operation either on the upper or the lower layer relies on the clutch that is equipped with this machine. When the clutch is on, the lower layer works. In contrast, as the clutch is turned off, the upper layer works instead.
● Reduced cost, increased efficiency
Adopting a double layer roll forming machine can reduce the cost that might be spent on purchasing several single layer roll forming machines when it is necessary to do so.
In addition, this machine also eliminates the need in transporting the workpieces from one unit to another, since one double layer unit can take the place of two single layer units, which increases the efficiency of the works as well.
● The versatility
When it comes to versatility, a double layer definitely surpasses a single layer roll forming machine, because of the double ability the former has in the fabrication of products.
● The required space
In the cases when different forms of productions are required, one double layer roll forming machine can replace two single layer roll forming machines, which reduces the space that is required in the factories.
● The cost
When the cost of purchasing the machines is a concern, applying one double layer roll forming machine is less expensive than two single layer roll forming machines.
In addition to the comparison between the double and single layer roll forming machines, there is still another alternative that is able to perform two forms of productions on one machine, which is the double row roll forming machine.
● The operation availability
The largest advantage of the double row roll forming machine over the double layer unit is that the former is capable of working on the two rows at the same time.
● The product length limitation
Since the two rows on the double row unit are equally placed on the same layer, the lengths of the rows are fixed and limited. In contrast, the range of the product length can be wider on the double layer unit.
● The efficiency
As the double row roll forming machine can perform on the two rows at the same time, while the double layer roll forming machine cannot, if the limitation of the product length is not a concern, the efficiency of the former would be higher than the latter.
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