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Shijiazhuang Faith Machinery Co.,Ltd introduces its Linear Cage Forming Profile Mills, designed to transform flat strip or sheet into complex, open‐section profiles such as reinforcement cages, frames, and support channels. The Linear Cage Forming Profile Mill integrates precise feeding, progressive forming, and tension control to produce profiles with consistent geometry, suitable for applications in automotive manufacturing, construction reinforcement, and industrial shelving.
Decoiling and Strip Conditioning
Hydraulic or mechanical decoilers feed flat strip—carbon or stainless steel, typically between 0.5 mm and 3 mm thick—into a tension‐leveling section.
Levelers eliminate residual curvature and camber, ensuring the material enters the forming stands flat and stress‐free.
Progressive Roll Forming Stands
A series of roll stands, often 12 to 20 in number depending on profile complexity, gradually bend the strip into the desired shape.
Each stand consists of precision‐machined upper and lower rolls mounted on adjustable bearings; roll gap adjustments are motorized for recipe‐driven changeovers.
Profile Alignment and Welding (Optional)
For closed or skeletal profiles, the mill can be equipped with inline seam welding units—MIG or laser welders—followed by seam trimming and bead removal stations.
Weld integrity is monitored through surface inspectors and ultrasonic testing modules.
Cut‐to‐Length and Stacking
Flying shears synchronized to line speed perform burr‐free cuts at programmed lengths up to 8 m.
Stacking arms and servo‐driven conveyors organize finished sections onto pallets or into bins for downstream processing.
Closed‐Loop Roll Adjustment: Laser micrometers positioned after the final forming stand measure outer dimensions in real time; feedback loops adjust roll positions to maintain tolerances within ±0.2 mm.
Tension Control Modules: Load‐cell sensors upstream and downstream of the forming sequence regulate strip tension, preventing profile distortion or edge waviness.
Tooling Calibration: Roll sets are pre‐calibrated on offline stands, enabling rapid swap‐in and swap‐out for different profiles, with calibration values stored in the PLC for quick recipe recall.
Profile Variety: Capable of producing U‐channels, C‐profiles, hat sections, wire cages, and complex multi‐bend formations.
Material Compatibility: Handles mild steel, galvanized strip, pre‐painted steel, and aluminum with minor roll material and gap adjustments.
Changeover Efficiency: Motorized roll change systems and position encoders reduce setup times to under two hours, making the mill suitable for batch production and just‐in‐time manufacturing.
Centralized PLC Control: All mill functions—coiler speed, roll stand servo positions, shear timing, and weld unit parameters—are managed via a single PLC network.
HMI Recipe Management: Touchscreen HMI allows operators to select profile recipes, monitor line status, and access maintenance prompts.
Data Logging and Traceability: Production data—including coil batch information, profile dimensions, and downtime events—are recorded to an SQL database for quality audits and process improvement.
Installation and Commissioning: Field service engineers guide the mill installation, commissioning, and initial trial runs to ensure target tolerances and throughput rates are met.
Operator Training: Hands‐on instruction covers profile changeover, troubleshooting, and routine maintenance tasks such as roll lubrication and bearing inspections.
Spare Parts Kits: Recommended spare parts—roll bearings, shear blades, sensor modules—are stocked to minimize unplanned downtime.
Remote Diagnostics: Optional VPN connectivity enables Shijiazhuang Faith’s support team to review control system logs, advise on parameter optimization, and resolve alarms without onsite visits.
