Roll Gap Adjustment for Quality Control
Roll gap adjustment is an essential part of roll forming process control and is necessary to maintain the desired quality of the product being rolled. The roll gap is the distance between the two rollers and is the gap in which the strip material is rolled through. It is important to maintain the proper gap size and shape throughout the entire process.
The proper gap size and shape is determined by several factors including: the material properties, the die design, and the type of process being used. For example, the gap between the upper and lower rollers need to be smaller for high-temperature materials than for lower temperature materials.
The shape of the roll gap affects the quality of the product. If the gap is too small, it will cause an increase in tension and friction on the material which can lead to material tearing, stretching, and cracking. If the gap is too large, it will cause the material to move out of the roll gap and deform the product.
The roll gap adjustment process involves two different approaches: manual adjustment and computer-controlled adjustment. Manual adjustment is still used in some modern roll forming machines, where the roll gap is adjusted by hand using a measuring device. This traditional approach allows for quick adjustments and is still used in high-volume production.
Computer-controlled roll gap adjustment has become increasingly popular due to its improved accuracy and high levels of repeatability. This type of system uses a computer-controlled device with a digital readout to adjust the roll gap. The device connects to two measuring sensors located on the upper and lower rollers. The sensor measures the gap and then commands the controller to adjust the gap to the desired level.
Roll gap adjustment is an important factor in maintaining the quality of the product being manufactured. It is necessary to ensure that the gap size and shape are maintained in order to maximize the productivity and minimize the risk of materials failure. Both manual and computer-controlled adjustment approaches are available to adjust the gap and maintain the desired gap size.
