Sen Fung Brochure

SEN FUNG
100 International Drive Peachtree City, GA 30269 770.631.0002
tel
metalforming-usa.com
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VIPRO SF 400 L & CL Machine Profiles
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VIPRO SF 400 L - Single Profile for Panels
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VIPRO SF 400 CL - Rafted Machine for Panels
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VIPRO SF 800 DL - Double Layer Machine Profiles
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VIPRO SF 800 DL – Double Layer Machine for Panels
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Vipro HD & Vipro HS – Heavy Duty & High Speed Rollforming Machines
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Decoilers and Coil Options
Page 14 & 15
Stacking Options
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Eclipse Production Management System
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Controls & Options
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Purlin Machine Profiles
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Vipro 460 L - Manual Purlin Machine
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Vipro SF 401 AL - Semi-Automatic Purlin Machine
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Vipro SF APL - Automatic Purlin Machine
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Stud Machine Profiles
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Vipro SF 240 L & 240CL- Stud Machine
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Patented Tile Machine Profiles
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Vipro SF 400 LN - Patented Tile Machine
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Traditional Tile Machine Profiles
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Vipro SF 400 LN - Traditional Tile Machine
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Trim Rollforming Machine Profiles
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Vipro SF 240L - Trim Rollforming Machine
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Tube Mill Profiles
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Tube Mill Machine
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Custom Rollforming Machine Profiles
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Vipro SF 401 LD - Custom Rollforming Machine
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Door Frame Machine Profiles
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Vipro SF 401 L - Door Frame Machine
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T-Bar Machine
MetalForming is the North American leader in
the development of innovative machinery
solutions for customers in the architectural sheet
metal and metal building industries. MetalForming
is not a manufacturer, but a machinery
development specialist free to match the right
manufacturer’s solution to the customer’s needs.
The company uses industrial engineering
techniques to define customer needs, problems
and opportunities. They then use these same
techniques to review companies’ capabilities to
address these needs before selecting the best
solution from their network of manufacturers in
the US, Germany, Switzerland, Austria and Taiwan.
reviewed the portfolio of over 40 rollforming
companies around the world in an effort to find a
company that could offer amazing quality and
excellent prices.
Based upon customers’ needs for solutions – lower
costs, better quality, better service and improved
packaging – with regard to the in-plant
rollforming sector, MetalForming launched a major
development process in 2002. MetalForming
Sen Fung was established in 1963 in Taipei,
Taiwan, and is the pre-eminent manufacturer of
rollforming machines in Asia. It is the leading
Sen Fung offered a widely diverse set of
machinery from panel machines to purlins to
specialized machines like ceiling bar machines,
automotive parts and tube mills. We believe Sen
Fung has more rollforming knowledge, more diverse
experience and more knowledge of customer
requirements because they are a customer. They
utilize more than 100 of their own machines in
their private label manufacturing business. No one
in the North American market can claim this.
manufacturer and exporter of rollforming
machines in Taiwan with over 30 patents. With
more than 40 years of experience and strict
quality control, their products meet European CE
and International Standards. MetalForming
features Sen Fung panel, purlin and tile machines,
as well as decoilers.
We could have introduced the Sen Fung line as it
was but we took a year to develop new models, new
levels of strength and new levels of flexibility. The
final product line is called the Sen Fung VIPRO line
of Rollformers (Variable Professional Rollformers)
— the best built, most flexible and affordable
solutions we could create.
Sen Fung products are fully supported by
MetalForming with a service team factory-trained
on the systems in Taiwan. Together, Sen Fung and
MetalForming will exceed customer expectations.
Sen Fung has an open source parts policy, which
means they provide all owners with the internet
addresses of their parts manufacturers to enable
customers to purchase direct without markups.
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VIPRO SF 400 L - Single Profile for Panels
VIPRO SF 400 L & 400CL
The VIPRO SF 400 L by Sen Fung is the
rollformer
of
choice
among
manufacturers producing panels such
as the AG panel, PBR or corrugated panel.
As a world leader in custom profile panel
machinery, Sen Fung is known for its ability
to create tooling for ever-changing and
diverse panel profiles. No other machine
demonstrates this talent better than the
VIPRO SF 400 L. It is designed specifically to meet the demands of
the North American marketplace with an exit shear that ensures
perfectly square panels and a rotary front shear that allows for
fast coil change out.
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Less efficient rollformers use station-to-station drive chains or even
long serpentine chains that need constant adjustment and are known for stretching, breaking and vibrating.
The VIPRO models avoid those problems and enhances quality through a power-transmission system
driven by high-precision worm gears – a state-of-the-art technology that not only produces more torque
and power but ensures that the rollers turn at the same, constant speed to deliver scuff-free panels.
Worm gear
transmission
system
Sen Fung also employs massive, inverter drive AC power motors with 30 horsepower to give the VIPRO more
power with more control and less upkeep - a vast improvement over hydraulic systems because it's faster,
cleaner and requires no upkeep. The VIPRO also features Mitsubishi PLC's touch-screen control system for
the creation of multiple batches and allows the operator to run the
machine in fully automatic or manual mode. The interface is clean,
simple and can store up to 60 batches.
The machines are built utilizing Copra Design CAD software, finite
element analysis and nested parts drawing technology. Each
machine has a CAD package of technical drawings, and each part is
numbered and referenced for easy ordering.
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Rafted Machine for Panels
VIPRO SF 400 CL – Rafted Machine for Panels
Precision cut spacers
The VIPRO SF 400 CL rafted rollforming machine
is the solution for manufacturers who
need future upgradeability and the
ability to produce different
types of corrugated roofing
panels, wall panels or decking. This allows
manufacturers who purchase the base unit and
one set of tooling the ability to add more tooling in
the future - this is the ultimate in expandability.
Operators will never end up with an obsolete machine
because the VIPRO SF 400 CL can always be upgraded to make
new products.
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The CL has a quick-change rafter that can be sized for specific
lifting capacity or style. Rafters can be made with as few as four
stantions of tooling (for lifting with small forklifts) or as many as 14
stantions (for lifting with overhead cranes).
By far, the CL is the most affordable rafted rollforming machine in the
North American market today. Once the mainframe is equipped, the
operator can manufacture high-quality products quickly and
effectively. And, because it is high-speed and maintenance-free, it
reduces labor costs. Total changeover time with in-feed adjustment is
about 30 minutes depending upon the specific tooling.
The CL offers the same quality as the VIPRO SF 400 L with frequency
inverter motors, chromed tooling, casted stantions for long life, and a
massive steel frame.
Massive exit shearing
Rafters can easily be moved in or out
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Wormgears ensure constant power
VIPRO SF 800 DL – Double Layer Machine for Panels
Double Layer Machine for Panels
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The VIPRO SF 800 DL is a double-layer rollformer that can be outfitted to
rollform two profiles and can changeover from one profile to the other
with the push of a button. The ingenious design raises and lowers the
entire machine, so there is no need for complicated conveyors and
stackers.
The DL has six precision
spindle ball screws that
move the entire machine
up and down, eliminating
material
stress,
expensive
double-high stackers and multi-level infeed systems. The DL has a smaller footprint than most machines on the market
and on average uses 15 percent more roller
sets than competitors, which translates
into longer-lasting tooling.
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The most attractive element of this
machine can be found in the quality of
panels it produces. Panels from the VIPRO SF
800 DL are superior to those of most machines on
the market for one key reason: The VIPRO uses more
roll stations, which means less bending per station and
less induced stress.
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The DL offers the same quality as the VIPRO SF 400 L with
precise PLC controls, frequency inverter motors, chromed tooling, casted stantions for long life and a massive steel frame.
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The VIPRO DL goes to another level with its optional equipment
potential and can be outfitted with integrated slitting so the operator
gets multiple machines in one: a flying shear, stacking units or side
discharge unloading equipment.
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Vipro HD & Vipro HS - Heavy Duty & High Speed Rollforming Machines
Heavy Duty & High Speed Machines
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Because Sen Fung has produced over 2,000 machines in 45 years, they
have a deep understanding of the need to be flexible which is clearly
evident in the company's product offering.
Heavy Duty Decking Machines
Sen Fung manufactures heavy duty machines for the production of
decking and flooring material all the way down to 16 ga. Options for this
type of machine include flying shears, stacking and embossing at high
speeds.
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Tooling is the best quality in the industry
Front shearing
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High Speed
Machines
Sen Fung produces all L,
CL and DL versions in a high
speed version reaching speeds of
up to 180 fpm. This type of machinery is
for manufacturers who demand the maximum
in throughput and want to pay 30 percent less
than most other machines on the market. Sen
Fung holds patents for high speed flying shears
and utilizes world-class LSK linear guide-ways in
conjunction with a 1.75 inch precision ball screw to
reach speeds of up to 180 fpm. Sen Fung also has patented technology
that integrates the flying shear into the actual stacking mechanism.
Hydraulics are protected
inside the frame
Strong in-feed mechanism ensures straight panels
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Decoilers & Coil Options
Decoilers & Coil Options
Sen Fung offers the most economical, high quality decoilers in the North
American market. The decoilers are cantilevered and can be used with
any system, from portable rollformers to slitters to competitive
rollformers.
The Sen Fung UC4C decoiler is a hydraulic, cantilevered decoiler with
a capacity of 22,500 lbs. It has an outside diameter of 48", an inside
diameter of 18.8 to 20.5", and is powered by a five-horsepower
hydraulic motor. It features hydraulic automatic expansion to tighten
the coil, and the decoiler is controlled by the machine PLC and
electro-mechanical sensor.
The Sen Fung UC3C decoiler is a hydraulic, cantilevered decoiler with
a capacity of 16,500 pounds and a five-horsepower hydraulic motor.
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UC2 offers double
sided loading
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The Sen Fung UC3B is a hydraulic, cantilevered decoiler with a
capacity of 11,000 lbs. and a three-horsepower hydraulic motor. Both
have an outside diameter of 48", an inside diameter of 18.8 to 20.5",
and a coil width of 48.03". They feature hydraulic automatic expansion
to tighten the coil, and the decoiler is controlled by electromechanical sensor. Hydraulic coil carts are available for both machines.
UC4 11,000 lb. decoiler and coil cart
The Sen Fung UC2C decoiler is a dual-head, non-powered decoiler
with a capacity of 7,260 lbs. on both sides, an outside diameter of 48",
an inside diameter of 18.8 to 20.5", and coil width of 24". It features
manual expansion to tighten the coil.
The Sen Fung UC1C decoiler offers the same features as the UC2C but
is one-sided, rather than two-sided - a perfect choice for customers
who want to move up from a two-sided decoiler to one that can be
loaded much more quickly.
UC 1 Decoilers are available in
2,000, 4,400 and 6,600 lbs.
Material flow is controlled by optical sensors
Decoiler with electronic
loop control & coil cart
Each decoiler can be outfitted with a coil cart for ease of loading and
coil safety. Sen Fung produces coil carts in 11,000 lb., 16,500 lb. and
22,000 lb. versions.
Coil carts are available
in 11,000, 16,500, and
22,000 lbs.
Stacking Options
Stacking Options
Sen Fung is one of the most innovative rollforming machinery
manufacturers in the world and they have brought their innovative
thinking to bear on the packaging side of the business. Stacking
or handling to ensure scratch-free panels is one of the most labor
intensive and hence costliest
parts of panel
production. Most
manufacturers
accomplish this with a
table and one or two men
carrying the end of the panel to avoid
scratching. With the stacking unit,
personnel are freed up to focus on
quality assurance and coil staging rather
than carrying the end of a panel - a huge cost saver.
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Single sided stacker
Sen Fung offers two stacking solutions. The SS Stacker is a
patented one-side stacking unit that can be purchased in 20
or 40-foot lengths. Its low cost and effectiveness makes it
the choice of most panel manufactures. The DS Stacker is a
bombay style stacker that can stack for machines reaching
speeds of up to 180 fpm. This stacker can be combined with a
side-discharge unit for the easy unloading and wrapping of
panels. The side-discharge unit can move panels to the side
and away from the line of production so that banding and
wrapping can take place while the machine is running.
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The Eclipse Production Management System
Controls & Options
The Eclipse Production Management System is
the platform software that links the production
scheduling office to the shop floor. It works
seamlessly with the AMS XL 200 control.
Downloading orders, uploading production data and real time machine
monitoring are automatically managed by Eclipse. Company-wide production
information is gathered from the production line and assembled into detailed
reports. These reports are information-based tools to make better-informed
decisions about process improvements and buying decisions.
The AMS XL200 Series Controller
is capable of controlling up to
sixteen machine outputs on
either stationary or flying die
applications. The control is
incredibly accurate with stop
to cut applications or flying
shear applications. The result
is substantially increased
production. Eliminate much of
the down-time experienced by
other length controllers with
the XL200 Series Controller's ability to program orders while the machine is
running. When the XL200 Series Controller is used with Eclipse Production
Management Software, orders can be scheduled and downloaded to the shop
floor, production monitored, and accurate time and material reports
generated. Expert installation and operator training are available. And the
control is made and serviced right here in America.
Download Orders
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Eclipse downloads orders directly from production scheduling to the machines
on the shop floor. This eliminates operator programming and avoids costly
errors. With a reduction in errors, production capacity can be increased by as
much as 40%.
Upload Production Data
Eclipse uploads information directly from the shop floor. Every inch of material
run through each machine is recorded. This feature allows Eclipse to track run
vs. idle time and reasons for every delay.
Base Module
Included in the Eclipse base module is a two-way communications package,
between the shop floor and production scheduling office. The base module also
includes order entry and downloading to each machine, as well as, real-time
status information.
Schedule Orders
Included in the Base Module of the Eclipse system is a Schedule Orders feature.
This feature allows you to schedule orders on an automated basis, reducing any
chance of order errors. Functions include:
• Assigning orders to machines based on product type
• Creating sequence for automatic download when machines run low on work
• Scheduling orders for download by a date and time
• Placing/recalling orders from machines immediately
• Printing order details
• Displaying orders for specific machines or all machines
• Selecting sets of orders using filter criteria
proportional to the amount of material moved. The controller counts these
pulses to determine how much material has moved. When the material reaches
a point where a punch is needed, the controller cycles a punch press. When the
material past the cutoff press is equal to the length programmed, the
controller cycles the shear press.
The XL200 Series Controller is capable of:
• Non-Stop presses, Feed-to-Stop presses or both
• Controlling 16 presses
• Controlling up to 100+ gags
• Controlling flying presses with multiple gags
• Counting Holes or Notches for Cutoff or punching operations
• Rotary Press Control
• Multiple X-Y Axis Punching & Machine Setup
• Controlling a Die Boost via +/- 10V Analog output proportional to line speed
• Controlling the Mill Speed via +/- 10V Analog output proportional to part
length
Real Time Status
The XL200 Series Controller is capable of integrating with several labor
saving products:
• Controlling machine speed in Single Speed or Two Speed operation
Reports
Eclipse monitors every machine on the network. This allows you to track orders
while in progress. This gives you the ability to see problems as they happen and
allows you to make faster decisions with less downtime.
The Base Module creates several reports for better records and vital
information. These reports include:
• Bundle Ticket Printer
• Ink Jet Printing System
• Controlling a line in Open Loop and Closed Loop configurations from
a single controller
• Orders and cut-list
• Label Applicator Printer
• Integrating with the QC100L Autocalibration & Length Measurement System
System Compatibility
• Order summary list
• Bar Code Scanner
Eclipse integrates easily into your system under Windows 9x, Windows NT,
Windows 2000 or higher, and also links with your EPR/MRP system. Eclipse
links your production scheduling office to 30 or more XL200 Series
machine controllers.
• Schedule details
Sen Fung has a strategic relationship with Seyi, one of the largest punching and
pressing companies in the world. They have produced hundreds of machines with
very complicated punch patterns. They have the capacity to make the LGSI
punching patterns is three forms of punching to meet the budget needs
• Order Sequence
• Orders summary
• Schedule details
• Communications Log
The XL200 Series Controller is an electronic length controller that is part of an
Open Loop control system. A wheel with a known circumference is attached to
a material encoder and rides on the material. As the material moves through the
machine, the wheel rotates and the encoder generates electric pulses
• Controlling two presses in an alternating mode
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Vipro SF 460 L — Manual Purlin Machine
Purlin Machines
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The SF 460 L is the original Sen Fung purlin rollforming machine. It can
run both Cee’s and Zee’s and can be changed over by manually
repositioning the precision-cut spacer collars. The standard machine,
without any modifications can produce 4, 5, 6, 8 and 10-inch wide
purlins from 16ga. to 11ga.
The web and flange dimensions on the part can be changed by adding or
removing spacers. To go from Cee to Zee, the operator
simply removes the stanchion on one side and
switches the tooling from top to bottom
in just 45 minutes.
This is the best solution for economical
purlin rollforming and a great machine
for the customer who makes large runs. The adjustable
in-feed mechanism allows for the rollforming of uneven
LGSI Cee’s and Zee’s.
The machine boasts one of the industry’s best and most
massive straightening fixtures, which delivers straighter parts
than most machines on the market. It also can be outfitted with
leveling, punching, large-entry conveyors and stacking/catch
frames.
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The 460 L can be outfitted to produce framing parts, racking parts and
storage parts and can be designed as a rafted machine to meet
customer needs.
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Vipro SF 401 AL — Semi Automatic Purlin Machine
Vipro SF APL — Automatic Purlin Machine
The SF 401 AL is the latest machine developed by Sen Fung with more
than 11 pending patents. As the perfect machine for customers
entering the lucrative purlin market, the SF 401AL can form 12-, 14- and
16-gauge Cee's and Zee’s with extremely fast changeover and minimum
down time. With automatic width adjustment, the machine is designed
so that only a small number of tooling parts rotate 180 degrees which
reduces the number of adjustments needed. The width can be
controlled by the PLC controlled induction motors that position
precision ground ball screws.
The Sen Fung APL is a fully automatic Cee's and Zee's Purlin machine that
takes just two minutes to change width, material thickness, punch
pattern and profile. The machine is bigger and stronger than other
machines on the market and is less expensive than comparable
products. It can produce 18 ga. to 10 ga. Cee's and Zee's from 4" to 12"
with almost no downtime for changeover.
Sen Fung has a strategic relationship with Seyi, one of the largest
punching and pressing companies in the world. They have produced
hundreds of machines with very complicated punch patterns and have
the capacity to make the LGSI punching patterns in three punching
forms to meet myriad budget needs.
The machine utilizes more roll
stations (30 to be exact) than other
machines on the market and also uses
more of a footprint. This enables the
machine to change material thickness and
the shapes and sizes of web flanges and lips
with the push of a button. On one side of the
machine, the entire forming heads rotate 180 degrees.
Unlike some machines on the market that rotate in the
vertical plane, each APL station rotates in a horizontal
plane.
The machine includes seven roll leveling (not a five
station coil set straightener), a mechanical press that is
sized to specific needs (110 tons is appropriate for the most
complicated patterns in 10 ga.) and a part straightener that is bigger
and stronger than anything currently on the market.
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Vipro SF 240 L & SF 240 CL – Stud Machine
Stud Machine
The SF 240 machine for manufacturing studs is the perfect machine for
manufacturers stepping up from a small mobile stud machine or for
those who want to begin manufacturing their own studs. Sen Fung
produces its stud machine in two levels:
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1.) A stop-to-cut machine at 80 fpm designed for customers who need
a low-entry cost to making studs.
2.) A 180-foot-per-minute machine with a flying shear and flying
punching. Sen Fung will customize machines at all levels in between.
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The machine can be bought as a stand-alone model that makes one
profile (SF 240 L) or as a rafted machine (SF 240 CL) that allows
operators to run Cee's, Zee's, base angle, U channel or hat channel.
As a standard, the machine can knurl the flanges that receive screws.
The machine includes computer-controlled punching that will punch at
the appropriate position for the alignment of plumbing or electrical
pass through. Options include stackers, wrappers and a conveyor for
maximizing throughput.
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Vipro SF 400 LN Patented Tile Machine
Patented Tile Machine
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The Sen Fung SF 400 LN Patented Roof Tile machine is the leading tile
producing rollformer in the world. Sen Fung holds patents in more than
30 countries around the world for this hybrid
rollforming and folding machine. It produces a
profile that has an adjustable depth and an
adjustable reveal that gives panels the true
appearance of clay tiles.
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This machine can produce through-fastened panels in steel
and is capable of forming two different roof tiles with the same
mold, creating a perfect, scrape-free finish. The machine design allows
for the production of traditional tile panels and fastened tile panels.
The step width and depth can be varied via the touch screen control.
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Vipro SF 400 LN Traditional Tile Machine
Vipro SF 400 LN Traditional Tile Machine
The Sen Fung SF 400 LN Traditional Roof Tile machine is the leading
tile-producing rollformer in the world. The traditional tile machine can
be purchased from a myriad of existing profiles or a profile can be custom designed to meet your needs. Tile panels are through fastened and
can be applied over shingled substrates. The machine can produce a
wide coverage panel as well as a tiled panel by simply turning the press
unit off. This gives the customer flexibility in what panel can be put on
a structure.
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Vipro SF 240 L — Trim Rollforming Machine
Trim Rollforming Machine
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The Sen Fung SF 240 L & CL & SF 400 L & CL machines are the perfect
solution for the production of sheet metal trim. Each machine is
custom designed and engineered to meet the customer's design
specifications. The machines can be outfitted with a flying shear and
conveyors for higher speed production. Unlike most trim rollforming
machines on the market, the machine produces one profile but can do
so in three gauges. Many machines on the market can't vary the gauge
and make a quality product.
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With the CL version, the customer can select many profiles to go on one
machine and add more profiles in the future.
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Tube Mill Machine
Tube Mill Machine
Sen Fung produces more than 12 different tube and pipe mills. The machines
can be segmented into two categories: carbon steel systems (the model SF
240 K series) and stainless steel systems (the model SF 240 A series).
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The machines generally are composed of a forming section, welding unit,
cooling section (tank), cleaning unit, final rollforming section and finally an
exit sawing unit.
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The machine is capable of reaching speeds of 300 feet per minute depending upon the models and thickness. Generally speed decreases as the
thickness of the steel increases.
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Vipro SF 401 LD — Custom Rollforming Machine
Custom Rollforming Machine
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Sen Fung is one of the premier custom rollform manufacturers in the
world. The company utilizes state-of-the-art engineering technology
such as Copra design software and finite element analysis to achieve
outstanding results.
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About 60
percent of the
machine
solutions
engineered each year are
custom applications, created
for the furniture, window, and automotive industries.
The machine pictured on this page was designed
to produce two racking component parts on one
machine base thereby saving the customer space, setup
time, and money.
It features advanced technology for which Sen Fung is known, including
flying shearing, THK guideways, conveyors exit assembly, worm gear drive
systems and a quick change power transmission system.
SF 401 L - Door Frame Machine
Door Frame Machine
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The SF 401 L is one of the most advanced machines in the world enabling
the operator to produce door frames to within .04" tolerance.
The machine notches, feeds, cuts-to-length and swages for hinges and
locks. The control allows the
operator to mirror the punching pattern to deliver a door
frame that slides together
and can be locked quickly
with integrated clips.
This fully automatic Door Frame
Rollformer features a servo drive
system and an advanced computer
control system which enables hole punching, angle punching and rollforming all in one
production line. There is also a spot-welding
feature with each corner pre-cut to a 45 degree angle
for an accurate fit.
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T-Bar Machine
As those in the industry know, a ceiling T-Bar machine is not one
machine but three: a Main T-Bar Machine; a Cross T-Bar Machine; and an
Angle Rollformer.
Vipro SF 240 CL – T-Bar with In Line Punching
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The Main T forming machine uses 20 HP inverter motors, producing a line
speed of 130 feet per minute. The machine utilizes hydraulic notching,
punching (up to 16 stations) and cutting and it is capable of achieving
extreme accuracies without secondary trimming.
The Cross T forming machine uses a 10 HP inverter motor to reach a line
speed of 130 feet per minute with flying shearing.
Also exclusively from MetalForming
folding
shearing
coil processing
Curving
portable Rollforming
Factory Rollforming
Tools
Accessories
Service
training
For more information please call 770.631.0002, and visit metalforming-usa.com.