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Roll Forming Machine Troubleshooting: Length Tolerance

roll forming machine troubleshooting

Roll forming machine troubleshooting is one of the basis skills of an operator. This article will show the reader some common problems and solutions about length tolerance

The Issues and Solutions

Length Measuring Unit( Mechanical)

Loose part of switch, limit stops, pins. Tighten or replace all the loosen parts

Length Measuring Unit( Encoder)

1. Encoder wheel worn. Adjust the tolerance coefficient or replace the encoder
2. Dirt on the wheel. Clean it
3. Roll Forming Runs at an angle to the encoder wheel. Correct the angle
4. Wheels jumps when the product vibrates. Eliminate jumping.
5. The encode position is at the entry side and the product stretches during the roll forming. Relocate encoder.
6. Encoder shaft bent. Replace it.

Other electric sensor

Incorrect setup, distance, angle, location, loose installation  or electric problems

All the sensing unit

Incorrect data entered by the operator. Incorrect location of a mechanical device

Mechanical presses

1. The press does not stop at the top limit center( TDC)
2. The clutch or brake broken
3. Inadequate air volume or pressure to operate the clutch and brake
4. Problem with pneumatic accessories or valves

Pneumatic presses

1. Insufficient quantity or low pressure air.
2. Problems with valves.
3. Incorrect timing or electric/electronic components.
4. Improperly set stroke.
5. Leaking hoses and other components.

Hydraulic presses

1. Hydraulic system problem (pressure, volume, problems with valves or other components, low pressure in the accumulator etc.).
2. Leaking hoses and accessory components.

Die rails

1. Lack of lubrication.
2. Dirt between the sliding parts.
3. Incorrectly set sensors.

Die accelerator

1. Speed is not adjusted to match the speed of the strip or product.
2. Die is not completely back in the home position.
3. Loose component.
4. Can be pneumatic, hydraulic, mechanical, or electrical problem, depending on the type of accelerator.

Roll Forming Machine Straightener

Speed of the product can be reduced or varied by incorrectly installed or too tight straightener.

Entry guide

Can have the same effect as the straightener, especially if the product width is changing or if heavy burr creates friction in the entry guide

Roll Forming Mill

1. Bent shaft(s) can create a pinch point and a loose point with each revolution. This will influence the speed of the product.
2. Depending on the roll design, passes set to different gaps can accelerate or decelerate the speed of the strip, which can influence length tolerance.
3. Bad bearings may act as continuous or intermittent brakes
4. Lubrication: uneven application of lubricant can contribute to fluctuating line speed.


1. Worn or incorrectly set brake can change the strip speed at each revolution of the uncoiler (not critical when positive stop is used)
2. Over tightened uncoiler arms (making a triangular or rectangular shape from the round coil) can vary the line speed (not critical when positive stop is used)

Roll Former Operator

1. Incorrect setup
2. Incorrect setting of gap between rolls
3. Incorrect setting of press, sensor, die accelerator, uncoiler brake

Believe Industry Company have a more than 15-years experience of roll forming machine troubleshooting, and have trained 1000+ skilled workers for the users of roll forming machines. If you want to buy roll forming machine or want to study roll forming machine troubleshooting. Contact us now.

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