Maximize Uptime: Roll Forming Preventative Maintenance

Action: Use a refractometer to verify the oil-to-water ratio matches the supplier's specification.

Why: Too much water affects machine performance and product quality.

Action: Inspect for excessive foaming, debris, or a foul odor. Ensure the coolant is clear. Clean coolant is essential to prevent rollers from sticking.

Action: Verify the oil level is within the sight gauge (check ambient temperature, as it may affect level).

Action: Confirm PSI levels are within the required operating range.

Action: Apply the minimum amount of lubricant required. Wipe off all excess grease immediately to prevent dirt attraction.

Action: Check all hydraulic and pneumatic hoses for leaking or visible weeping.

Why: Leaking hydraulic oil is a major safety hazard.

Action: Check high-pressure hydraulic hoses for rubbing on each other or on equipment portions. Report rubbing immediately for clamp installation.

Action: Wipe down piercing dies and forming rolls. Clear away metal shavings and debris that can embed in rolls or dies.

Action: Visually confirm knurl rolls are not set too deep. They should only provide a slight indentation. Deep setting stretches the material and causes straightening problems.

Action: Listen for unusual noises (e.g., knocking, rough bearing sounds) and check for excessive vibration or localized heat (e.g., hot gearboxes, motors). Report all abnormalities immediately.

Action: Check the nitrogen gas pressure using a gauge to maintain design pressure. Must be done by trained personnel.

Why: Pressure drop leads to excessive “bag” folding and failure, causing downtime.

Action: Apply grease to roll former shaft bearings operating under heavy loads. Do not over-lubricate.

Action: Thoroughly check for abrasion and leaks/weeping along the entire length.

Action: Install proper hose separator clamps wherever hoses show signs of rubbing abrasion.

Action: Verify the in-line filter indicator is securely in the Green range. If it moves to Yellow, schedule a filter change. If it reaches Red, the filter is in bypass mode and provides no filtering.

Action: Perform a major leak check when the plant is idle and quiet. Turn on the compressor, listen for leaks, and repair all found.

Action: Visually inspect the position of shafts and tooling stands. Look for signs of shifting or unusual stress on the frame.

Action: Check the tension on all motor drive belts (including the flattener) and adjust tension to OEM specifications.

Action: General best practice is twice per year, or determined by microscopic oil analysis relative to hours of usage (e.g., AW-32 oil).

Action: Drain all EP-320 gear oil (or manufacturer spec.) and replace it. Refill only to the sight gauge.

Action: Clean the base of the tank. Manually move the shaft inboard/outboard to check end-play and tighten the nut on the shaft end. Rotate the shaft and check the rotational quality of bearings; change bearings exhibiting rough sounds.

Action: Remove access covers and wipe the reservoir floor with solvent-soaked, lint-free wipers to remove accumulated sludge, gasket pieces, and hose fines.

Action: Send a sample of the hydraulic oil to a service firm for analysis. This determines the “ideal time period” for future oil changes.

Action: Remove and clean screens in the air filters using solvents. Accumulated dirt clogs filters and reduces cooling efficiency.

Action: If applicable, ensure softened water is used (in hard water areas) to prevent scale buildup in pipes. Check pressure filters.

Action: Lubricate these points, as they typically operate under lighter load conditions.

Action: Stop the line with material engaged. Cut samples between passes and compare the profile to engineered roll drawings to assess wear.

Action: Audit piercing tooling inventory. Establish minimum re-order levels and discard “short” or worn tooling to reduce unscheduled downtime.

Action: Change the synthetic automatic transmission fluid (e.g., Amsoil, Mobil). Found on flatteners and pinch rolls.

Action: It is imperative to filter oil through a 10 micron (or better) filter to remove impurities *before* adding it to the equipment during fills or changes.

Action: Requires sharpening to maintain a clean shear. Monitor tool length—tools become “short” over time and must be replaced.

Action: Adjust the tensioner mechanism (usually within the flattener housing) to set the ideal tension.