How Do Rectifiers Used in Roll Forming Lines Work?

Rectifiers are critical components in roll forming lines that ensure that metal sheets are properly fed and processed. In this way, it is aimed to minimize errors in the production process and to increase product quality.

Task of Rectifiers:

• Sheet Straightening: To bring metal sheets in rolls or with slight curvatures to a flat surface, which is necessary for the roll forming process.
• Tension Control: To ensure a smooth flow by adjusting the tension of the sheet while it is fed towards the roll forming machine.

• Plate Orientation: To ensure that the roll forming process is carried out correctly by directing the plate to the desired position and angle.

Rectifier Types and Working Principles:

• Mechanical Rectifiers:
  • Roller Rectifiers: It consists of a series of cylinders. The sheet is leveled as it passes between these rollers. The diameter, spacing, and surface properties of the rollers are adjusted according to the thickness and material of the slab.
  • Bending Straighteners: It  is based on the principle of flattening the plate by bending it slightly. This method is more suitable for thick plates.
• Hydraulic Rectifiers:
  • The plate is passed between the trimming elements, which are supported and moved by hydraulic cylinders. In this way, a more precise and controlled correction process is performed.
• Magnetic Rectifiers:
  • The sheet is attracted and flattened with the help of powerful magnets. This method is especially suitable for materials with magnetic properties.

Importance of Rectifiers:

• Product Quality: An uneven sheet can lead to errors and a decrease in product quality during the roll forming process.
• Efficiency: A properly adjusted rectifier increases production speed and reduces machine wear.
• Occupational Safety: A properly functioning rectifier reduces the risk of occupational accidents.

Rectifier Selection:

The choice of rectifier should be made according to the type, thickness, width and production speed of the material to be processed. In addition, the capacity of the roll forming machine and the precision of the product to be produced are also important factors in the selection.

Result:

Rectifiers used in roll forming lines are vital for the smooth machining of metal sheets. Different types of rectifiers are designed to meet different needs. The right choice of rectifier has a direct impact on the efficiency of the production process and product quality.