This marvel of engineering is a four-roller plate rolling machine, where the top roller is meticulously designed as the main driving force, ensuring seamless rotational movement. is at the heart of the system, enabling the lower roller to execute precise up-and-down movements. This action allows the plate to experience friction along its length, while the two side rollers perform synchronized up-and-down movements at an angular trajectory. Such movements are instrumental in achieving the desired plastic deformation of steel plates. By adjusting the side rollers, both symmetric and asymmetric bending can be realized, minimizing the flat ends to a theoretical minimum. Unlike the traditional three-roller apparatus, this sophisticated machine eliminates the need for pre-bending procedures and devices, simultaneously offering rough leveling of steel plates. It finds extensive utility across various sectors including petroleum, chemical, boiler, shipbuilding, hydroelectricity, metal structures, and the machinery industry.
Machine Construction:
The machine's robust body structure is ingeniously composed of an upper roller device and driving mechanism, lower roller device,side roller assembly, hydraulic drop-end mechanism, lubrication system, and essential components like the left and right frames, and chassis.
(Refer to body frame drawing)
Top Roller and Driving Device:
The top roller device comprises a top roller, hydraulic drop end, fixed bearing, hydraulic motor, and a robust bearing.
The top roller transmits torque through a well-integrated hydraulic motor, allowing it to perform efficient
rotational movements. The hydraulic drop end is secured with a protective steel bushing, ensuring durability.
Lower Roller and Position Inspection Device:
The lower roller device features a lower roller, oil cylinder, lower roller bearing, and a self-aligning bearing for optimal performance.
Sliding bearing blocks on either side support the lower roller, working in harmony with the frame guide rail. These are anchored on dual oil cylinders, with the hydraulic system empowering the lower roller's up-and-down movements. The main oil cylinder's rated pressure is 16Mpa. A sensor provides real-time inspection of the lower roller's position, displayed on an LCD. The adjustable hydraulic system ensures the necessary power is easily accessible, matching the rolling power required.
(Refer to hydraulic drivers drawing)
Side Roller Device:
This component comprises the main oil cylinder of the side roller, self-aligning bearing, and support bearing, designed for peak efficiency.
The bearing block bolsters the side roller, coordinating seamlessly with the frame guide rail.
Through the synchronized action of four oil cylinders within the frame, side roller bearing blocks orchestrate precise up-and-down movements. This motion is monitored by sensors and displayed on an LCD for transparency and accuracy.
For crafting cone shapes, the self-aligning bearings of the side and lower rollers collaborate effectively. By fine-tuning, the lower roller maintains its level or adapts to a sloped line, ensuring perfect alignment between horizontal and inclined planes.
3-4, Hydraulic Drop End:
Comprising an oil cylinder, oil cylinder joint, bearing block, and oil cylinder bearing, this device is engineered for efficiency and precision.
The hydraulic drop end device is designed for effortless product removal along the roller shaft. Upon completion of the hydraulic drop's closure or opening, the oil cylinder returns to its zero stroke position.
The hydraulic station serves as the powerhouse, driving this essential mechanism. The power source derives from a specialized hydraulic station.
Balance Device:
The innovative balance device features a sleek, compact structure that ensures stability when the tipping rack slips off the top roller's bearing face. As the roller tips, gravity causes one end of the top roller to drop, but the balance device cleverly maintains a level position. Positioned on the fixed side, beyond the fixed frame for optimal distance, it is securely attached to the frame with screws, optimizing performance.
(plate rolling drawing)
Hydraulic System
The hydraulic system is a well-orchestrated assembly of a gear pump, valve group, and auxiliary pipelines, designed for seamless operation.
The hydraulic valve integrates the reliable Yuken superposition hydraulic valve series, ensuring simplicity in the pipeline layout. out
The design is straightforward, minimizing leakage and streamlining maintenance.
The system's architecture comprises three loops: pressure adjustment, synchronization, and speed control, each enhancing operational efficiency.
The pressure adjustment loop finely tunes the system's working pressure via the main overflow valve, maintaining a steady pressure of 16Mpa.
The synchronization loop ensures precise, in-phase adjustments of the lower roller's vertical movements through a flow divider and throttle valve. The throttle valve allows for meticulous speed adjustments.
The speed loop manages the control frames' drop, reset, and speed alterations with the precision of a throttle valve.
Electric Control System
The electric control system incorporates an electric cabinet, an operational control table, and a portable button box, all powered by 380V/50Hz. Equipped with short-circuit and overload protection for the main motor, it features AC contactors for controlling rotation direction. Utilizing advanced PLC programmable control, it boasts minimal relay use, exceptional stability, and longevity. With all necessary buttons and indicator lights accessible on the control table, it offers comprehensive control over the rolling process and working status.
CNC System
This NC system employs a rotational encoder paired with a highly reliable industrial controller, crafting a robust control system with unwavering performance.
CNC Function
CThe NC system assures real-time monitoring, seamless data transmission, and memory retention even during power interruptions in the rolling process.
An industrial control PLC automatically inspects the lower position and both ends of the side rollers, ensuring synchronization precision within ±0.15mm.
A programmable display provides a real-time view of the lower roller position and the two side roller ends, with adjustable settings.
position and it can be set.
The displacement transducer offers a resolution of 0.10mm, with a display precision of ±0.10mm, guaranteeing accurate readings and control.
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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