In northern winter zones or regions like Central Asia, where temperatures frequently plummet below 0°C, the operating conditions of a roll forming machine undergo significant physical variations. Sub-zero temperatures not only spike hydraulic fluid viscosity and slow electrical responses but also introduce microscopic changes to the yield strength of the steel substrates.

To prevent hydraulic pump failure, profile paint cracking, or out-of-tolerance dimensions under freezing conditions, operators must strictly adhere to the following winter operational and maintenance protocols.

The hydraulic system represents the most vulnerable section of a roll forming machine during winter. When ambient temperatures drop below 0°C, the fluidity of standard hydraulic oil degrades sharply.

• Hydraulic Fluid Adjustments: Under winter or sub-zero operations, the standard No. 46 fluid must be drained and replaced with lower-viscosity, lower-pour-point No. 32 Anti-Wear Hydraulic Oil (AW32), or specialized low-temperature hydraulic oil.

• Mandatory Preheating Routine: Never execute hydraulic shearing immediately after a cold start in freezing weather. Prior to daily production shifts, the hydraulic pump station must run an idle cycle for 10 to 15 minutes. Main line feeding should only commence once the fluid temperature reaches above 15°C through physical circulation. Otherwise, high-viscosity oil will cause pump cavitation, instantly damaging the internal plungers or gears due to localized vacuum pockets.

At low temperatures, standard lubrication grease applied to the chains, gearboxes, and main shaft bearings of the roll forming machine can freeze and harden, losing its lubricity.

• Transition to Winter-Grade Grease: Standard No. 2 lithium grease becomes wax-like in sub-zero climates, causing spikes in mechanical resistance and motor current overloads. Operators should transition to No. 1 Lithium-Based Grease or dedicated low-temperature anti-freezing greases.

• Low-Speed Mechanical Warm-Up: Before running production material, program the PLC control enclosure to run the primary drivetrain at a low line speed of 5 m/min for 3 to 5 idle cycles. This motion allows the gear oil inside the speed reducer (e.g., CKD 220) to heat up naturally via mechanical friction, restoring standard oil film thickness and preventing hard scoring on gear faces during high-speed operation.

Physically, steel alloys exhibit "Cold Brittleness" when exposed to freezing environments, which alters their yield strength and elongation limits.

• Preventing PPGI Paint Cracking: At temperatures below -10°C, the paint film on pre-painted galvanized iron (PPGI) coils becomes brittle, making it susceptible to cracking or peeling during the forming stages. It is highly recommended to store the steel coils in a heated indoor bay for at least 24 hours to normalize their temperature before processing.

• Roller Gap Tolerance Inspections: Thermal contraction can cause micron-level shifts in the physical fit between the roll forming machine main shafts and the forming rollers. Before initiating a winter run, operators must use a feeler gauge to re-verify the gaps between rollers. This ensures uniform formatting pressure across all stations and prevents over-compression due to metal contraction, which can deform profile edges or overload the main shafts.

Rapid temperature shifts in freezing environments frequently trigger physical condensation inside sealed electrical enclosures.

• PLC Moisture Safeguards: As the workshop heats up or the machinery generates operational heat, moisture suspended in the air condenses into droplets upon hitting freezing PLC modules or Variable Frequency Drives (VFDs). This condition easily triggers short circuits and component burnouts. The interior of the PLC control enclosure must be inspected for dry conditions before boot-up, and adding industrial desiccant silica packets inside the cabinet is highly recommended throughout the winter season.