Introducing our latest innovation: a state-of-the-art Precision Steel Roll Forming machine with a Hydraulic Four Roll mechanism. This engineering marvel positions the top roller as the linchpin of its operation, delivering the precision and finesse that our esteemed clientele demand. It serves as the primary drive, seamlessly executing rotational movements with unparalleled grace. The lower roller ascends and descends with elegance, expertly guiding the plate while ensuring perfect friction alignment along its length. The two side rollers, with their fluid, angular up-and-down motion, transform the steel plate with the desired plastic deformation. With the adaptable side roller, this machine effortlessly masters symmetric and asymmetrical bending, achieving a minimal flat end that surpasses traditional three-roller machines. By eliminating cumbersome pre-bending procedures and devices, it offers rough leveling of the steel plate, making it an indispensable tool across industries like petroleum, chemical production, boiler manufacturing, shipbuilding, hydroelectricity, metal structures, and machinery.
Machine construction:
The core structure of this advanced machine is composed of the upper roller device and driving unit, lower roller device, side roller apparatus, hydraulic drop end system, lubrication unit, exceptionally durable left and right frames, robust chassis, and more sophisticated components.
(body frame drawing)
top roller and driving assembly
The Top roller device ingeniously combines a top roller, a hydraulic drop end, fixed bearing, hydraulic motor, and bearing, all functioning in perfect harmony.
The top roller transmits torque via an adeptly connected hydraulic motor, initiating its smooth and efficient rotation. A protective steel bushing is meticulously fitted with the hydraulic drop end.
movement. This hydraulic drop end is expertly equipped with a protective steel bushing, ensuring seamless operation and lasting durability.
lower roller and position inspection unit
The lower roller device consists of a meticulously designed lower roller, oil cylinder, lower roller bearing, and a self-aligning bearing, all tailored for optimal performance.
Each sliding bearing block, supporting the lower roller, aligns flawlessly with the frame's guide rail. Mounted on two oil cylinders, the hydraulic system provides the precision power for up-down movement of the lower roller. The primary oil cylinder operates at an impressive rated pressure of 16Mpa, while sensors meticulously track the up-down distance, displaying the data on an LCD. This meticulously adjustable hydraulic system ensures precise power delivery to meet the desired rolling force, elevating accuracy to unprecedented levels.
(hydraulic drivers drawing)
side roller apparatus
The side roller device is intricately crafted with the side roller's main oil cylinder, self-aligning bearing, and other essential bearings.
Bearing blocks provide steadfast support to the side roller, with each side seamlessly coordinating with the frame's guide rail for optimal function and efficiency.
The up-down movement of the side roller bearing block is driven by four strategically placed oil cylinders within the frame. Sensors, installed on both the side rollers and frame, meticulously measure the movement, which is displayed on an LCD for convenient monitoring.
To achieve a beautifully refined cone shape, self-aligning bearings are utilized for both side and lower rollers. By adjusting the lower roller level and alignment to become inclined, you achieve a precise fit between lower and side rollers, introducing a precise degree of inclination relative to the horizontal, ensuring exquisite precision.
3-4, hydraulic drop end
The hydraulic drop end device includes robust oil cylinders, joints, bearing blocks, and other components, ensuring outstanding efficiency.
The hydraulic drop end system ensures effortless and efficient product removal along the Roller shaft, dramatically streamlining operations.
After completing the hydraulic drop closure or opening, the oil cylinder's stroke is ingeniously reset to zero, maintaining impeccable precision.The power source of our Precision Steel Roll Forming with Hydraulic Four Roll Machine is reliably provided by a state-of-the-art hydraulic station. This ensures a seamless and consistent performance, making it a cornerstone of efficiency and reliability for your operations.
Balance Device
Ingeniously crafted to revolutionize balance, our state-of-the-art balance device features a cutting-edge, compact structure that ensures unparalleled performance. As the tipping rack gracefully slips from the bearing face of the top roller and initiates its elegant tipping motion, this advanced balance apparatus comes into play. As gravity gently pulls the top roller's end downward, this expertly designed mechanism maintains perfect equilibrium. Strategically positioned on the fixed side, it is placed at a meticulously calculated distance from the fixed frame, securely anchored by premium screws to guarantee unwavering stability and exceptional operational efficiency.
(Plate Rolling Drawing)
Hydraulic System
Our hydraulic system is truly a masterpiece of precision engineering. Meticulously assembled with a high-precision gear pump, an intricate valve group, and premium auxiliary pipelines, it ensures flawless and smooth operation.
The hydraulic valve incorporates the renowned Yuken superposition series, ingeniously ensuring that the pipeline layoutis
remarkably intuitive, significantly reducing leakage and simplifying maintenance, which culminates in exceptional operational efficiency.
This sophisticated architecture features three distinct loops: the pressure adjusting loop, synchronization loop, and speed loop. Each loop is meticulously designed to contribute to harmonious and efficient operations.
The pressure adjusting loop skillfully modulates the system’s working pressure through the main overflow valve, achieving a robust pressure of 16Mpa, assuring consistent and reliable performance.
The synchronization loop deftly fine-tunes the synchronized movement of the lower roller via precise flow dividers and throttle valves, enabling impeccable speed adjustments to enhance operational precision.
The speed loop artfully governs frame descent, reset operations, and speed calibrations with precision, utilizing the adept throttle valve to ensure smooth and accurate adjustments.
Electric Control System
Our electric control system is a marvel of modern engineering. It features a seamlessly integrated electric cabinet, an advanced operation control table, and a versatile portable button box, all operating at 380V/50Hz. Equipped with robust short circuit and overload protection for the main motor, it employs an AC contactor to manage both positive and reverse rotations. Through the power of PLC programmable control technology, this system minimizes relay usage, enhancing both stability and longevity. Strategically placed buttons and indicator lights on the control table ensure a streamlined rolling process, efficiently managing every operational aspect with precision.
CNC System
The NC system stands as a paragon of reliability, incorporating a rotational encoder and a high-reliability industrial controller, providing a steadfast and dependable control platform.
CNC Function
CThis advanced NC system offers unparalleled real-time monitoring, effortless data transmission, and dependable power-off memory throughout the entire rolling process, ensuring efficiency and reliability.
The industrial control PLC meticulously inspects the lower position and both ends of the side roller, guaranteeing synchronization precision with an impressive ±0.15mm accuracy, ensuring superior operational outcomes.
The state-of-the-art programmable display provides comprehensive real-time visibility of the lower roller and side roller end positions,
and these parameters can be effortlessly configured and set to meet precise requirements, enhancing customization and control.
With an extraordinary displacement transducer resolution of 0.10mm, the display precision achieves an impressive ±0.10mm accuracy, setting a new standard for precision.
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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