Discover the pinnacle of modern engineering with our Automatic Four Rollers Rolling Machine, designed specifically for precision steel bending applications. This cutting-edge marvel features four rollers, with the top roller being the linchpin of its innovative plate rolling mechanism. It functions as the driving force with seamless rotational movements. The lower roller moves with precision to elevate the plate, flawlessly aligning it through friction along its length. The two side rollers, with their fluid up and down angular movements, elegantly sculpt the steel plate, achieving the necessary plastic deformation. The adjustable side roller offers an array of bending possibilities, both symmetric and asymmetric, minimizing flat ends and surpassing traditional three-roller machines by negating the need for pre-bending processes and devices. Furthermore, it provides preliminary leveling of the steel plate, making it an essential asset across various industries such as petroleum, chemical, boiler manufacturing, shipbuilding, hydroelectricity, metal structures, and machinery.
Machine construction:
At the heart of this sophisticated apparatus lies the upper roller device and driving unit, lower roller devicee, side roller apparatus, hydraulic drop end system, lubrication unit, and robust left and right frames, supported by a durable chassis and more.
(body frame drawing)
Top Roller and Driving Assembly
The Top roller device is a sophisticated assembly comprising the top roller, hydraulic drop end, fixed bearing, hydraulic motor, and bearing. This intricate setup ensures superior performance.
Through a connected hydraulic motor, the top roller initiates rotation, channeling torque seamlessly. A robust protective steel bushing accompanies the hydraulic drop end.
movement, enhancing durability. The hydraulic drop end is fortified with a protective steel bushing for optimal protection.
Lower Roller and Position Inspection Unit
The lower roller device is expertly designed with components including the lower roller, oil cylinder, lower roller bearing, and a self-aligning bearing, ensuring flawless operation.
Each sliding bearing block, meticulously supporting the lower roller, aligns perfectly with the frame's guide rail. Mounted on dual oil cylinders, the hydraulic system empowers the lower roller's precise up-down movement. Operating at a rated pressure of 16Mpa, sensors meticulously track movement, displaying real-time data on an LCD. Adjustable pressure within the hydraulic system guarantees accurate hydraulic power to fulfill the desired rolling force.
(hydraulic drivers drawing)
Side Roller Apparatus
The side roller device is a complex assembly, featuring the main oil cylinder, self-aligning bearing, and additional bearings, forming a cohesive unit.
Supported by bearing blocks, the side roller harmoniously collaborates with the frame's guide rail, ensuring smooth operation.
Driven by four strategically positioned oil cylinders within the frame, the side roller bearing block executes its precise up-down movement. Sensors within the side rollers and frame provide accurate measurements, with data presented on an LCD screen for easy monitoring.
To craft an exquisite cone shape, self-aligning bearings are employed for both side and lower rollers. Fine adjustments allow the lower roller to align perfectly, introducing a desirable inclination relative to the horizontal, achieving a snug fit.
3-4, Hydraulic Drop End
The hydraulic drop end device is meticulously assembled with oil cylinders, joints, bearing blocks, and more, ensuring reliable functionality.
The hydraulic drop end system facilitates seamless product removal along the roller shaft, enhancing efficiency and ease of use.
Following the completion of hydraulic drop closure or opening, the oil cylinder's stroke is effortlessly reset to zero, ensuring readiness for the next operation.This advanced mechanism is powered by a dependable hydraulic station, providing consistent and reliable performance.
Balance Device
The balance device stands as a marvel of engineering, boasting an innovative compact structure that ensures unparalleled performance. When the tipping rack gracefully slips off the bearing face of the top roller and the tipping movement begins, this ingenious balance device takes center stage. As gravity elegantly guides the top roller’s end downward, the balance device’s strategic positioning on the fixed side masterfully maintains equilibrium. This calculated placement, at an optimal distance from the fixed frame and securely fastened by screws, guarantees unwavering stability and efficiency.
(plate rolling drawing)
Hydraulic System
Our state-of-the-art hydraulic system is a masterpiece of design, meticulously crafted with a high-precision gear pump, an advanced valve group, and auxiliary pipelines to ensure seamless operation with exceptional precision.
The hydraulic valve utilizes the renowned Yuken superposition series, creating a pipeline layout thatis
remarkably straightforward. This intelligent design minimizes leakage and simplifies maintenance, delivering efficiency that is simply unmatched.
The system’s architecture is intelligently composed of three unique loops: the pressure adjusting loop, synchronization loop, and speed loop, each contributing to a symphony of harmonious operations.
The pressure adjusting loop expertly modulates the system’s working pressure through the main overflow valve, achieving a powerful working pressure of 16Mpa with precision.
The synchronization loop precisely fine-tunes the in-phase movement of the lower roller via the flow divider and throttle valve, allowing for exquisite speed adjustments.
The speed loop effortlessly controls frame descent, reset operations, and speed adjustments, all expertly managed through the throttle valve.
Electric Control System
The electric control system is an integrated marvel, featuring an electric cabinet, a sophisticated operation control table, and a portable button box, all operating seamlessly at 380V/50Hz. Built with robust short circuit and overload protection for the main motor, the system utilizes an AC contactor to manage positive and reverse rotations. By leveraging PLC programmable control technology, it boasts minimal relay usage, enhancing stability and longevity. Carefully placed buttons and indicator lights on the control table streamline the entire rolling process, overseeing every operational facet with eloquent precision.
CNC System
The NC system is a pinnacle of design, incorporating a rotational encoder and high-reliability industrial controller to establish a consistently reliable control system.
CNC Function
CThis sophisticated NC system offers cutting-edge real-time monitoring, seamless data transmission, and dependable power-off memory throughout the rolling process.
The industrial control PLC automatically inspects the lower position and both ends of the side roller, delivering synchronization precision of an impressive ±0.15mm.
The programmable display provides real-time visibility of the lower roller and side roller end positions,
and these parameters can be effortlessly configured and set with ease.
With a displacement transducer resolution of 0.10mm, the display precision achieves an extraordinary ±0.10mm.
Automatic Self-Judge Function
Manufacturer of the Standard Parts
| NAME |
Manufacture |
| Bearings |
Type |
Double row aligning bearing
|
| Manufacture |
Wafangdian |
| Rollers |
Material |
42CrMo forging upper roller and 45# steel other rollers |
| Manufacture |
Nangang/Warwick Steel
|
| Body frame |
Material |
Q235A |
| Processing methods |
Welded structural parts, annealing stress - shot blasting, CNC boring and milling machine machining
|
| Manufacture |
Pully |
| Hydraulic driver |
Jieshite |
| Hydraulic motor |
Nantong tongde |
| Main electrical element |
SIEMENS |
| Hydraulic system |
Pump |
Type |
Gear pump |
| Manufacture |
Changyuan |
| Valve |
Manufacture |
YUKEN |
| cylinder |
Piston rod |
45 Forgings, Heat treatment HRC48-52
|
| Manufacture |
Nantong |
| Sealing |
Yx |
| Manufacture |
NOK/dingji |
Electric system
|
|
digital control system |
| Hydraulic motor |
Nantong tongde |
| Touch screen |
Haiwei 15.6' |
| PLC |
XINJE |
| Sensor |
Milante |
| Main electrical element |
SchneiderElectric/Siemens |
Audited Supplier 
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