Solar Steel Frame Roll Forming Machine（Open frame)

I. Equipment Introduction
The Solar Steel Frame Roll Forming Machine (Open Frame) is a fully automated cold-bending forming machine specifically designed for producing steel frames for photovoltaic modules. This equipment uses a continuous cold-bending roll forming process to complete the entire process of uncoiling, cold bending, straightening, length cutting, automatic corner code assembly, and automatic stacking in one go, directly producing finished frames that can be directly used for photovoltaic module encapsulation.
The entire production line process is as follows: Double-head uncoiling and feeding → Multi-pass cold bending forming → Straightening → Tracking flying shear cutting → Conveying → Automatic corner code assembly → Automatic stacking. The entire line adopts PLC fully automated control, enabling continuous automated operation from uncoiling to finished product stacking.
This equipment features a double-head uncoiling design, allowing for continuous material changes without stopping the machine, significantly improving production efficiency. The equipment integrates automatic corner code assembly and automatic stacking functions, truly achieving one-stop delivery "from steel strip to finished frame that can be directly assembled." The entire line requires only 1-2 people for monitoring, making it a core piece of equipment for photovoltaic frame manufacturing companies to achieve automation and intelligent upgrades.

II. Core Advantages and Selling Points
(1) Double-Head Uncoiling, Zero-Downtime Continuous Production
Utilizing a double-head material rack design, one roll of material automatically continues when the other runs out. This achieves true non-stop continuous production, completely eliminating downtime for changing rolls. It significantly improves equipment utilization and capacity.

(2) Multi-Pass Cold Bending Forming, High Precision Guaranteed
Employing a multi-pass progressive cold bending forming process, the gradual change steps of the cross-section are precisely designed. Taking into account factors such as deformation, roll parameters, cross-sectional stability, and the torsional characteristics of asymmetric deformation stress release, the product boasts high straightness and good consistency. Production speeds can reach 10-30 meters/minute, meeting the needs of large-scale continuous production.

(3) Straightening + Tracking Flying Shear, Precise Dimensions
Equipped with an online straightening device after forming to ensure the straightness of the edge. The tracking flying shear cutting system automatically sets the length and tracks the cutting online. High cutting precision and a clean cut are achieved. Length dimensions are strictly completed according to drawing tolerances in one step, eliminating the need for secondary processing.

(4) Automated Corner Code Assembly, Eliminating Subsequent Assembly Steps
This is the core advantage of this equipment compared to traditional frame production lines.
Traditional frame production requires the cold-bent frames to be transferred separately to the corner code assembly process for manual or semi-automatic assembly. This not only increases process flow and labor costs but also suffers from inaccurate positioning and low efficiency. This equipment integrates automatic corner code assembly at the end of the production line. The formed and cut frames directly enter the corner code assembly station via a conveyor line.
The equipment is equipped with automatic corner code feeding, automatic insertion, and automatic pressing mechanisms. The corner code parts are automatically conveyed through a conversion channel and guided to the appropriate angle, where they are precisely pushed into the edge of the frame by the push-in component. The corner code and frame form an interference fit, ensuring a secure assembly. The entire process is fully automated, requiring no manual intervention, no additional equipment, and no intermediate transfers.
Saves on processes: Eliminates the need for a separate corner assembly station and equipment investment.
Saves on labor: Eliminates the need for dedicated corner assembly operators.
Saves on time: Eliminates inter-process transfer and waiting time.
Higher precision: Online automatic assembly ensures precise positioning and excellent product consistency.

(5) Automated palletizing for neat finished product output.
Equipped with a fully automatic palletizing machine, finished product edges automatically enter the palletizing station via a conveyor line. They are automatically stacked and arranged according to a set program, resulting in neat and orderly stacking. No manual handling is required, significantly reducing labor intensity and achieving "outgoing products are immediately put into storage."

(6) Advantages of Steel Frames, the Market Trend
The steel photovoltaic frames produced by this equipment have significant advantages over traditional aluminum frames:
Cost reduction of approximately 40%: Replacing aluminum with galvanized aluminum-magnesium steel significantly reduces overall costs.
Twice the strength of aluminum frames: Ultra-high strength mechanical properties allow them to withstand higher wind and snow loads.
Thermal expansion coefficient matches that of glass: Effectively reduces the risk of microcracks in modules caused by temperature changes.
High efficiency and environmental friendliness: Carbon emissions from production are far lower than those of aluminum frames, and steel has a high recycling rate.

(7) Intelligent Control, Easy Operation
Fully automatic PLC control, touchscreen human-machine interface, intuitive and convenient parameter settings. The entire production line is automated from uncoiling to palletizing, requiring only 1-2 people for monitoring. Automatic fault diagnosis and alarms facilitate rapid troubleshooting and maintenance.

III. Technical Specifications
Item Parameter
Applicable materials: Galvanized sheet, Al-Zn coated sheet, Zn-Al-Mg coated sheet, etc.
Material thickness: 0.55–0.8 mm (customizable)
Production line speed: 0–30 m/min
Roll material Cr12MoV
Cutting method: Flying shear (tracking cut)
Corner connector assembly: Fully automatic in-line assembly
Stacking method: Fully automatic stacking
Control system: Fully automatic PLC control
Operators: 1–2 persons
Equipment footprint: Approx. 37 m (L) × 7.5 m (W) (including operation and maintenance aisles)

IV. Production Process
Double-head uncoiling/feeding → Multi-pass cold roll forming → Straightening → Tracking flying shear cutting → Conveying → Automatic corner connector insertion → Automatic palletizing
Process Step Description
Double-head uncoiling/feeding: Alternating uncoiling from dual material reels enables continuous production without stopping the line.
Multi-pass cold roll forming: Progressive cold roll forming shapes the steel strip into the frame profile through multiple passes.
Straightening: Inline straightening ensures the straightness of the frame.
Tracking flying shear cutting: Automatic length setting and inline tracking cut-off ensure high precision.
Conveying: Automatic transport to the corner connector insertion station.
Automatic corner connector insertion: Automatic feeding, positioning, and pressing of corner connectors into the frame ends.
Automatic palletizing: Finished products are automatically stacked and discharged neatly.

V. Application Areas
Steel frame products manufactured by photovoltaic (PV) frame cold-roll forming machines are widely used in the following areas:
PV Module Manufacturing: Frame encapsulation for various single-glass and double-glass PV modules—steel frames offer high strength and low cost, making them an ideal alternative to traditional aluminum frames.
Ground-Mounted PV Power Plants: Large-scale ground-mounted plants—steel frames withstand higher wind and snow loads, making them suitable for harsh outdoor environments.
Commercial and Industrial Distributed PV: Rooftop distributed PV projects—lightweight steel frame designs reduce the load on roofs.
Bifacial PV Modules: Steel frame cross-section designs minimize rear-side shading, fully unlocking the power generation potential of bifacial modules.
BIPV (Building-Integrated Photovoltaics): The thermal expansion coefficient of steel frames matches that of glass, reducing the risk of micro-cracking.

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; engineers hold all necessary visas and are available for on-site service worldwide at any time.

VII. Why Choose Us
Nearly 20 years of manufacturing experience: Mature technology, refined processes, and reliable quality
End-to-end integration capabilities: One-stop delivery covering everything from uncoiling, forming, and cutting to corner connector insertion and palletizing
Core technology for automatic corner connector insertion: Eliminates the need for subsequent assembly steps and equipment, significantly saving labor and time
Specialized expertise in steel frames: Deep understanding of the technical intricacies of steel frame forming processes
Direct manufacturer: No middlemen, offering excellent value for money