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Purlin Quick-Change Equipment Series
CZU+Cap Quick-Change Roll Forming Machine
CZU+Cap Quick-Change Roll Forming Machine
CZU+Cap Quick-Change Roll Forming Machine
CZU+Cap Quick-Change Roll Forming Machine
CZU+Cap Quick-Change Roll Forming Machine
CZU+Cap Quick-Change Roll Forming Machine
CZU+Cap Quick-Change Roll Forming Machine
CZU+Cap Quick-Change Roll Forming Machine

CZU+Cap Quick-Change Roll Forming Machine

The CZU+Cap Quick-Change Roll Forming Machine is a flexible production line developed based on the production of multi-specification profiles, capable of handling C-shaped, Z-shaped, U-shaped, and other customized cross-section products. Its modular design enhances production flexibility, making it suitable for large-scale steel structure manufacturing enterprises.

CZU+Cap Quick-Change Roll Forming Machine (1–3mm thickness) — Professional manufacturer, high-speed continuous production, three profiles in one machine, integrated punching and forming, intelligent and efficient.

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I. Equipment Introduction

The CZU+Cap Quick-Change Roll Forming Machine is a high-speed cold-roll forming system designed specifically for producing C-channel, U-channel, and "Ji"-profile steel sections used in photovoltaic (PV) mounting structures. Named for its cross-section resembling the Chinese character "Ji", the "Ji"-profile steel serves as a crucial structural component—such as uprights, main beams, and purlins—offering significant advantages like high strength and rigidity. Utilizing a continuous cold-roll forming process, the machine transforms galvanized steel coils into finished profiles in a single, integrated workflow. This process encompasses uncoiling, leveling, shear-welding, a 10-station punching system with servo feeding, a spiral accumulator, roll forming, servo-tracked hydraulic flying cutting, and discharge.
The entire line features fully automatic PLC control and a touchscreen HMI, ensuring a continuous, automated workflow from uncoiling to finished product discharge. A single machine can produce all three profile types—C-channel, U-channel, and "Ji"-profile—enabling "one machine, three profiles" flexibility. It integrates a non-stop continuous production system (combining shear-welding and a spiral accumulator) with a high-precision punching unit (featuring a 10-station system and servo feeding); punching and forming occur synchronously, eliminating the need for secondary processing. The line utilizes a synchronous gearbox drive system for stable and reliable operation.
The equipment is compatible with various materials—including galvanized steel, Al-Zn coated steel, Al-Mg-Zn coated steel, and black steel strip—handling thicknesses from 1.0 mm to 3.0 mm. It produces a wide range of specifications, including C-channel, U-channel, and "Ji"-profile steel (with adjustable base widths of 50–200 mm and web heights of 30–150 mm), at a continuously adjustable production speed of 10–40 m/min. Requiring only 1–2 operators for monitoring, this system is essential equipment for PV mounting manufacturers aiming to achieve high-speed, intelligent, and large-scale production.


II. Core Advantages and Selling Points

(1) One Machine, Three Profiles: Flexible Production
This is the core advantage distinguishing this equipment from conventional single-specification production lines.
Traditional cold-roll forming equipment is typically customized for a single specification; changing profiles requires dismantling rollers and repeated adjustments, resulting in long downtimes and high costs. This equipment features a modular design, enabling the production of three profile types—C-channel, U-channel, and Hat-channel (Omega-shaped) steel—on a single machine. It accommodates a wide range of common dimensions, covering base widths of 50–200 mm and web heights of 30–150 mm. Profile switching is performed via a one-touch PLC interface; no mold changes or specialized technicians are required, allowing standard operators to handle the switch. This significantly boosts equipment utilization and drastically shortens lead times for small-batch, customized orders.

(2) Shear-and-Butt Welding + Spiral Accumulator: True Continuous Production Without Downtime
This represents the core technical advantage distinguishing this equipment from conventional production lines.
Shear-and-Butt Welding: When the current steel coil runs out, the system automatically shears and butt-welds the new coil to the old one, ensuring a seamless transition.
Spiral Accumulator (Material Buffer): After welding, the accumulator automatically stores material, providing a continuous and stable supply of steel strip to the subsequent forming process.
True Zero-Downtime Operation: Coil changes occur without stopping the machine, completely eliminating downtime associated with coil replacement and increasing equipment utilization by over 30%.
Suitable for Mass Production: Ideally suited for high-volume, long-run continuous production requirements, such as manufacturing photovoltaic mounting structures.

(3) 10-Station Punching System + Servo Feeding: Integrated Punching and Forming
The equipment integrates a 10-station punching system with a high-precision servo feeding system, accurately punching various hole types—such as mounting holes and connection holes—before the steel strip enters the forming machine. Punching and forming proceed synchronously and continuously, eliminating the need for separate punching stages, secondary positioning, or intermediate material handling. 10-Station Design: Capable of performing multi-pattern and multi-position punching in a single pass, exponentially increasing efficiency.
Higher Precision: Punching is performed on the flat strip; the servo system ensures precise positioning, keeping hole location deviation within ±0.5mm.
Higher Efficiency: Punching and forming occur simultaneously, adding no extra time to the production cycle.
Lower Costs: Eliminates the need for separate punching equipment and operators; two processes are completed in a single step.

(4) High-Speed Production, Leading Capacity
The entire line integrates automated processes including uncoiling, leveling, punching, forming, and cutting. Production speed is continuously adjustable between 10–40 m/min, with a daily output capacity of 3,000–6,000 meters. A servo-tracking hydraulic flying-cut system automatically tracks and synchronizes with the continuously moving profile to perform fixed-length cutting without slowing down or stopping the line. Fully automated production requires only 1–2 operators for monitoring, resulting in efficiency several times higher than traditional production methods.

(5) High-Precision Forming, Superior Quality
Utilizes a multi-pass progressive cold-roll forming process (typically 20–30 passes); mold design and forming parameters are optimized via precision algorithms to ensure product accuracy at the source. Forming precision reaches ±0.5mm, meeting industry standards for photovoltaic mounting systems. Key components are made of high-quality mold steel subjected to vacuum heat treatment, ensuring a long service life for the rollers. Product straightness and twist meet specifications, effectively preventing installation and assembly misalignments.

(6) Significant Labor Savings, Reduced Overall Costs
The CU/Ji-shaped steel cold-roll forming machine requires only 1–2 operators for monitoring; the line is highly automated, ensuring continuous operation from uncoiling to discharge. While traditional production methods incur labor costs of 30–50 RMB per ton, this equipment costs only 10–20 RMB per ton—a saving of 20–30 RMB per ton. Labor costs are reduced by over 60%, completely eliminating the inefficiencies and high labor intensity associated with traditional production lines.

(7) Robust, Durable, Stable, and Reliable
The machine frame features a heavy-duty welded steel structure that has undergone aging treatment; it offers high rigidity and excellent vibration resistance, ensuring no deformation during long-term, high-speed operation.
The drive system utilizes a synchronous gearbox mechanism—with each forming stand independently driven—ensuring smooth and reliable operation.
Rollers are made from high-quality mold steel, offering superior hardness and wear resistance.
Key electrical components are sourced from internationally renowned brands.
Critical components come with a 5-year warranty, ensuring a low failure rate and a long service life.

(8) Intelligent Control and User-Friendly Operation
Fully automated PLC control with a touchscreen HMI enables comprehensive digital management of the entire process. Operators can configure profile specifications, production speeds, punching parameters, and cut lengths via the interface with a single touch, and the system automatically adjusts settings accordingly. The machine is equipped with real-time monitoring and fault warning systems; it automatically triggers alarms and displays the cause of the fault in the event of an anomaly.

III.Technical Parameters

Item Parameter
Applicable Materials: Galvanized steel, Al-Zn coated steel, Al-Mg-Zn coated steel, black steel strip, etc.
Material Thickness: 1.0–3.0 mm
Profile Types: C-channel / U-channel / Hat-shaped profile (Omega profile)
Profile Dimensions: Base width 50–200 mm; web height 30–150 mm (adjustable)
Multi-profile Capability: C-channel + U-channel + Hat-shaped profile (one-key switching)
Forming Precision ≤±0.5 mm
Punching Precision ≤±0.5 mm
Production Speed 10–40 m/min (steplessly adjustable)
Daily Capacity: 3,000–6,000 meters
Punching System: 10-station punching system + servo feeding
Non-stop system: shear & butt welding + spiral accumulator
Cutting Method: Servo-tracking hydraulic flying cut
Drive System: Synchronous gearbox drive
Control System: Fully automatic PLC control
Operators: 1–2 persons


IV. Production Process

Uncoiling → Leveling → Shearing & Butt-welding → 10-Station Punching System + Servo Feeding System → Spiral Looper → Roll Forming → Servo-tracking Hydraulic Flying Cut-off → Discharge

Process Step Description
Uncoiling: Hydraulic uncoiler supports the steel coil and ensures stable material feeding
Leveling: Multi-roller leveler performs precision leveling to eliminate internal material stress
Shearing & Butt-welding: Automatic shearing and butt-welding of coil ends allows for continuous operation during coil changes
10-Station Punching + Servo Feeding Servo-controlled precision positioning; 10 stations enable punching of various hole types
Spiral Looper: Automatically accumulates material to ensure a continuous, stable supply for downstream processes
Roll Forming: Multi-pass progressive cold-roll forming; one-touch switching between C, U, and Hat (Ω) profiles
Servo-tracking Hydraulic Flying Cut-off: Servo-synchronized cutting enables precise length cutting without stopping the line
Discharge: Finished products are discharged in an orderly manner


V. Application Areas

The C-channel, U-channel, and "Ji"-shaped (arch-profile) steel products manufactured by the CU+ "Ji"-profile cold-roll forming machine are widely used in the following sectors:
Photovoltaic (PV) New Energy (Core Application): Core structural components for PV mounting systems—such as uprights, main beams, and purlins. The equipment processes materials like carbon steel and aluminum-magnesium-zinc-coated steel to produce key parts for both fixed and tracking mounting systems. The "Ji"-shaped profile is a crucial type of cold-formed open section used in PV mounting systems, frequently serving as uprights and purlins.
Architectural Steel Structures: Structural components such as C/Z-section purlins and light-gauge steel framing (furring channels/studs).
Warehousing and Logistics: Profiles such as uprights and beams for storage racking systems.
Greenhouses: "Ji"-shaped profiles serve as vital load-bearing beams and purlins; their unique arch-like structure effectively directs the flow of condensation droplets.
Seismic Bracing: Core profiles for building seismic support systems.
Automotive Manufacturing: Lightweight profiles such as vehicle body panels and chassis longitudinal beams.

VI. Service & Support

Solution Design: Personalized equipment selection and production line layout based on customer product drawings, capacity requirements, and target markets.
Custom Manufacturing: Support for non-standard customization, with full control over the entire process—from roll design to complete line manufacturing.
Installation & Commissioning: On-site installation, commissioning, and operator training provided by engineers to ensure rapid production startup.
After-Sales Support: Long-term technical consultation and spare parts supply; 5-year warranty on key components; engineers hold valid visas and are available for on-site service worldwide.
Continuous Optimization: Equipment modification and capacity upgrade services available to adapt to changing production needs.

VII. Why Choose Us

Nearly 20 years of manufacturing experience: Mature technology, refined processes, and reliable quality.
"Three-in-One" capability: A single machine handles C-channel, U-channel, and Hat-channel profiles, eliminating the need for redundant investment.
High-speed continuous production: Speeds of 10–40 m/min; shear-and-weld plus spiral accumulator systems enable true non-stop production.
Integrated 10-station punching: Online punching and forming occur simultaneously, saving on equipment, labor, and time.
High-precision manufacturing: Forming accuracy of ±0.5 mm, meeting industry standards for photovoltaic mounting systems.
High efficiency and energy savings: Operated by 1–2 people with a daily output of 3,000–6,000 meters; saves 20–30 RMB in labor costs per ton.
Direct manufacturer: No middlemen, offering excellent value for money.
Global service network: Engineers hold all necessary visas, ensuring rapid response.

Item Specification
Forming machine structure Cast-iron gantry frame with gearbox drive.
Hoisting/lifting profile forming modules 2 sets (for producing different specifications of hoisting profiles).
Connection between gearbox and forming module Jaw-type coupling (with pneumatic shift fork for quick mold changes).
Main motor power 22 kW x 2 (K-series gear reducers).
Line speed 0–30 m/min (including punching and shearing speed of 0–20 m/min; actual speed depends on the number of punching operations).
Number of forming stations Forming Module 1: Approx. 14 stations plus auxiliary rollers; Forming Module 2: Approx. 20 stations plus auxiliary rollers.
Specification adjustment Automatic lateral shifting for producing different specifications.
Lateral shifting motor power 0.75 kW x 2 units + 1.5 kW x 1 unit.
Shaft material 40Cr steel, quenched and tempered (HB 220–260).
Shaft diameter Forming Module 1: Φ 60/80 mm; Forming Module 2: Φ 50/70 mm.
Roll forming tooling 2 sets.
Roller material Cr12MoV, quenched (HRC 58–62).
Spacers To minimize shaft runout, spacers are machined from thick-walled tubing to ensure geometric tolerances and maximize contact area with the rollers; the inner bore features a clearance fit with the shaft.
Straightening mechanism Turkish-style straightening head
Safety guards Protective cover installed on the drive side
Cooling system Spray cooling unit installed
Shear mechanism structure Post-forming hydraulic cut-off with servo tracking
Shear die base Welded steel plate with tempering treatment; CNC machined
Shear dies 4 sets (provisional; to be verified against actual CAD drawings)
Shear die material Cr12MoV, quenched (HRC 58–62)
Servo motor power 5.5 kW
Linear guides and ball screws Well-known domestic brands
Hydraulic system power 15 kW
Solenoid valve voltage 24 V (safety voltage)
Hydraulic station pump Plunger pump
Hydraulic station cooling method Air cooling

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Uncoiling – Leveling – Shearing and Butt-welding – 10-Station Punching System + Servo Feeding System – Spiral Looper – Roll Forming – Servo-tracking Hydraulic Flying Shear – Discharge

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About
Wuxi Yanwu Xinhui Technology Co., Ltd.

Established in 2012, Wuxi Yanwu Machinery Co., Ltd., is a professional manufacturer specializing in the R&D, design, manufacturing, and servicing of cold roll forming equipment. The company is dedicated to providing global customers with integrated solutions for automated cold roll forming production lines.

Our main products include cable tray forming machines, racking forming machines, C/Z purlin machines, solar mounting bracket forming machines, floor deck machines, door frame machines, automotive profile equipment, and cut-to-length/slitting lines.

These products are widely used in the construction, electrical power, logistics and warehousing, automotive manufacturing, new energy, and infrastructure sectors.

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News
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