Behold the marvel of engineering: our four-roller plate rolling machine, a state-of-the-art creation where the top roller takes command. It serves as the primary drive, performing a graceful rotation. The lower roller gracefully ascends and descends, guiding the plate along its length with precision. Meanwhile, the two side rollers execute an angular up-down movement, sculpting the steel plate into the desired plastic deformation. This ingenious design allows for both symmetric and asymmetric bending, minimizing the flat end and eliminating the need for pre-bending processes and devices, a feat unmatched by traditional three-roller machines. This versatile machine is a cornerstone in the petroleum, chemical, boiler, shipbuilding, hydroelectric, metal structure, and machinery industries.
Machine construction outlined:
At its core, the machine boasts a sturdy structure comprising an upper roller device and a sophisticated driving mechanism, lower roller device,side roller device, hydraulic drop end device, and a comprehensive lubrication system, all housed within the robust left and right frames and chassis.
(Refer to body frame drawing)
The top roller and driving device
At the heart of this mechanism, the top roller assembly features a hydraulic drop end, fortified fixed bearings, a powerful hydraulic motor, and highly efficient bearings.
The transmission of torque occurs seamlessly from the hydraulic motor to the top roller, enabling
fluid rotation. Equipped with a protective steel bushing, the hydraulic drop end ensures maximum durability.
Lower roller and position inspection device
The lower roller assembly, a masterpiece of engineering, includes the lower roller itself, precision oil cylinders, and a self-aligning bearing system.
Its sliding bearing blocks harmoniously interact with the frame guide rail, powered by dual oil cylinders. The hydraulic system provides dynamic force for the lower roller's vertical motion, supported by a 16Mpa-rated main oil cylinder. Movement accuracy is ensured by sensors interfacing with an LCD display. The hydraulic pressure is easily adjustable to meet the exact rolling power requirements.
(Refer to hydraulic drivers drawing)
Side roller device
The side roller assembly incorporates the main oil cylinder, expertly designed self-aligning bearings, and precision-engineered support bearings.
The bearing block steadfastly supports the side roller, synchronizing seamlessly with the frame guide rail.
With the ingenuity of four oil cylinders, the side roller bearing block executes an elegant vertical dance, monitored precisely by sensors and displayed vividly on an LCD.
For the creation of cone-shaped forms, self-aligning bearings for both the side and lower rollers ensure optimal alignment, adapting when the lower roller transitions from level to inclined positioning, maintaining tight contact through subtle adjustments.
3-4, Hydraulic drop end device
The hydraulic drop end apparatus is a finely tuned composition of oil cylinders, joints, and bearing blocks.
The hydraulic drop end system facilitates effortless removal of the finished product along the roller shaft.
Upon completing its cycle, the oil cylinder stroke returns to zero, ensuring seamless closure and opening operations. This power is fueled by the hydraulic station, a heartbeat of innovation.
Balance device: ensuring equilibrium and stability throughout the process.
The brilliantly engineered balance device features a compact structure designed for optimal functionality. When the tipping rack slips off the bearing face of the top roller, initiating a tipping movement, the top roller will naturally descend due to gravity. To counteract this and maintain the top roller's level, our balance device is strategically installed on the fixed side, with a calculated distance from the fixed frame. This ingenious device is then securely fastened to the frame using robust screws.
(plate rolling drawing)
Hydraulic System
Our hydraulic system is a sophisticated blend of high-performance components, consisting of a gear pump, a precise valve group, and meticulously arranged assistant pipelines.
The hydraulic valve is expertly crafted from the renowned Yuken superposition hydraulic valve series, ensuring unmatched reliability. The pipeline lay out
is thoughtfully designed to minimize leakage, offering exceptional simplicity and ease of maintenance.
This advanced system is composed of three essential loops: a pressure adjusting loop, a synchronization loop, and a speed loop.
The pressure adjusting loop is engineered to precisely control the system's working pressure through the main overflow valve, maintaining a consistent pressure of 16Mpa.
The synchronization loop allows for precise in-phase adjustment of the lower roller, utilizing a flow divider valve and throttle valve for fine-tuned speed control, both up and down.
The speed loop efficiently manages frame drop and reset, fine-tuning speed with precision through the throttle valve.
Electric Control System
The electric control system is an integration of cutting-edge technology, comprising an electric cabinet, operation control table, and portable button box. Powered by a reliable 380V/50Hz supply, it features advanced short circuit and overload protections for the main motor. Directional control is achieved via an AC contactor, while the system employs a PLC programmable controller for reduced relay use, heightened stability, and extended operational life. The intuitive control table hosts all buttons and indicator lights necessary to seamlessly execute the rolling process, managing the entire operation with unparalleled precision.
CNC System
Our NC system is equipped with a rotation encoder, seamlessly integrated with a high-reliability industrial controller to create a system with exceptional stable performance.
CNC Function
CThe NC system offers real-time monitoring, data transmission, and power-off memory retention, ensuring consistent performance throughout the rolling process.
The industrial control PLC automatically inspects the lower position and both ends of the side roller, maintaining synchronization precision with an impressive ±0.15mm accuracy.
The programmable display provides real-time visualization of the lower roller and side roller positions, which can be adjusted with ease.
Each position is easily settable, ensuring maximum control and precision.
The displacement transducer offers an impeccable resolution of 0.10mm, with a display precision of ±0.10mm, ensuring the utmost accuracy.
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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