Introducing our Precision Steel Plate Roll Forming Machine with Hydraulic Control: a cutting-edge four-roller plate rolling masterpiece, where the top roller shines as the pivotal element driving innovation. It serves as the primary drive unit, executing refined rotational movements, while the lower roller skillfully ascends and descends, guiding the plate with grace. This dynamic action ensures precise frictional alignment along its length. The pair of side rollers perform a sophisticated dance, moving up and down at calculated angles, bestowing the desired plastic transformation upon the steel plate. With the side roller's adjustability, this machine achieves both symmetric and asymmetrical bending, minimizing flat ends. This offers a superior advantage over traditional three-roller devices by negating the requirement for pre-bending setups and delivering preliminary leveling of steel plates. This indispensable tool finds essential applications across industries such as petroleum, chemical, boiler manufacturing, shipbuilding, hydroelectricity, metal structures, and machinery production.
Machine construction:
The intricate framework of this advanced machine encompasses the upper roller mechanism and driving assembly, lower roller device, side roller system, hydraulic drop end mechanism, lubrication ensemble, left and right frameworks, base chassis, and more.
(body frame drawing)
Top roller and driving assembly
The Top roller device showcases the top roller, a hydraulic drop end, steadfast bearing, hydraulic motor, and encompassing bearing.
The top roller imparts torque via an integrated hydraulic motor, initiating its smooth rotation. A durable steel bushing accompanies the hydraulic drop end for enhanced protection.
movement. The hydraulic drop end is fortified with a protective steel bushing, ensuring reliability.
Lower roller and position inspection unit
The lower roller device is comprised of the lower roller, oil cylinder, lower roller bearing, and expertly aligned self-adjusting bearing.
Mounted on precision sliding bearing blocks, supporting the lower roller, each aligns seamlessly with the frame guide rail. Positioned on two oil cylinders, the hydraulic system empowers the lower roller's vertical movement. The primary oil cylinder operates at a rated pressure of 16Mpa. Sophisticated sensors track the movement, displaying measurements on an LCD. The adjustable pressure within the hydraulic system ensures precise power delivery to achieve the desired rolling force.
(hydraulic drivers drawing)
Side roller apparatus
The side roller apparatus intricately includes the main oil cylinder, self-aligning bearing, and a series of supportive bearings.
Bearing blocks uphold the side roller, with each side seamlessly integrating with the frame's guide rail.
The movement of the side roller bearing block is driven by four strategically installed oil cylinders within the frame. Sensors on the side rollers and frame precisely measure the motion, with results vividly displayed on an LCD screen.
For crafting an exquisite cone shape, self-aligning bearings are utilized for both side and lower rollers. This allows the lower roller level to adjust and the alignment to incline, ensuring a perfect fit between lower and side rollers, introducing a slight inclination relative to the horizontal plane.
3-4, Hydraulic drop end
The hydraulic drop end device is composed of oil cylinders, coupling joints, bearing blocks, and additional components.
The hydraulic drop end system facilitates the seamless removal of finished products along the Roller shaft, ensuring efficiency and precision.
Upon the conclusion of hydraulic drop closure or opening, the oil cylinder's stroke conveniently resets to zero for streamlined operations.A robust hydraulic station provides the power source, ensuring unwavering reliability and performance.
Balance device
Our state-of-the-art balance device is ingeniously crafted with a cutting-edge, compact structure, ensuring unparalleled performance. When the tipping rack gracefully slips off the bearing face of the top roller and initiates its tipping movement, this advanced balance device comes into play. As gravity naturally draws the top roller's end downwards, this expertly designed apparatus maintains perfect equilibrium by being thoughtfully positioned on the fixed side. This strategic placement, at a meticulously calculated distance from the fixed frame, is firmly anchored by high-quality screws, guaranteeing stability and exceptional operational efficiency.
(plate rolling drawing)
Hydraulic System
Our cutting-edge hydraulic system is a masterpiece, meticulously assembled from a high-precision gear pump, an intricate valve group, and premium auxiliary pipelines to ensure flawless operation.
The hydraulic valve features the acclaimed Yuken superposition series, which ingeniously ensures that the pipeline layoutis
astonishingly intuitive, significantly reducing leakage and simplifying maintenance for exceptional efficiency.
This sophisticated system architecture incorporates three distinct loops: the pressure adjusting loop, synchronization loop, and speed loop, each meticulously contributing to a harmonious and efficient operation.
The pressure adjusting loop expertly modulates the system’s working pressure utilizing the main overflow valve, achieving a robust working pressure of 16Mpa, ensuring consistent performance.
The synchronization loop deftly fine-tunes the in-sync movement of the lower roller through the precise flow divider and throttle valve, allowing for impeccable speed adjustments.
The speed loop artfully manages frame descent, reset operations, and speed calibrations with precision, through the adept use of the throttle valve.
Electric Control System
Our electric control system is a marvel of engineering, featuring a seamlessly integrated electric cabinet, an advanced operation control table, and a versatile portable button box, all functioning at 380V/50Hz. Equipped with robust short circuit and overload protection for the main motor, and utilizing an AC contactor for managing both positive and reverse rotations. Through the power of PLC programmable control technology, this system boasts minimal relay usage, enhancing stability and longevity. Strategically placed buttons and indicator lights on the control table ensure the entire rolling process is streamlined and efficiently managed, with every operational aspect scrutinized with precision.
CNC System
The NC system is a paragon of reliability, designed with a rotational encoder and a high-reliability industrial controller, creating a steadfast and dependable control system.
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 of an impressive ±0.15mm.
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 suit precise requirements.
With an extraordinary displacement transducer resolution of 0.10mm, the display precision reaches an impressive ±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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