Introducing a state-of-the-art marvel in the world of industrial machinery: a four-roller plate rolling wonder that stands as a pinnacle of innovation. This Precision Steel Bending Machine boasts a top roller as its crowning glory, leading the charge in its flawless operational design. purpose as the primary powerhouse, orchestrating rotational movements, while the lower roller majestically ascends and descends, guiding the plate into perfection with elegant precision. The ingenious design ensures friction aligns immaculately lengthwise, while two side rollers, like artists, craft the steel plate by imparting sublime plastic deformation. The adjustable side roller empowers this machine with the versatility of both symmetric and asymmetrical bending, minimizing flat ends and surpassing traditional three-roller systems by eliminating pre-bending necessities and offering preliminary leveling of the steel. Its role is pivotal across a spectrum of industries: from petroleum to chemical, boiler manufacturing to shipbuilding, hydroelectricity to metal structures, making it an indispensable asset in the machinery realm.
Machine construction:
The fundamental framework of this sophisticated machinery features a top roller device and driving unit, a lower roller device,a side roller apparatus, a state-of-the-art hydraulic drop end system, a lubrication unit, robust left and right frames, a sturdy chassis, and additional components.
(body frame drawing)
top roller and driving assembly:
The Top roller device is an intricate assembly of the top roller, hydraulic drop end, fixed bearing, hydraulic motor, and bearing, a testament to engineering excellence.
Through a seamlessly connected hydraulic motor, the top roller transmits torque effortlessly, initiating its rotational journey. The protective steel bushing, seamlessly integrated with the hydraulic drop end, ensures operational safety.
movement. The hydraulic drop end is fortified with a protective steel bushing to enhance durability.
lower roller and position inspection unit:
The lower roller apparatus comprises the lower roller, a precision oil cylinder, lower roller bearing, and a self-aligning bearing, all harmoniously working together.
Each sliding bearing block is meticulously aligned with the frame guide rail to support the lower roller. It is ingeniously mounted on dual oil cylinders, with the hydraulic system delivering precise up-down movement power for the lower roller. Operating at a rated pressure of 16Mpa, the main oil cylinder ensures optimal performance. Sensors track the up-down distance, displaying the data on an LCD for real-time monitoring. The adjustable pressure in the hydraulic system guarantees that the hydraulic power precisely matches the desired rolling force, ensuring unparalleled accuracy.
(hydraulic drivers drawing)
side roller apparatus:
The side roller device is a masterpiece, intricately composed of a main oil cylinder, self-aligning bearing, and other precision bearings.
Bearing blocks provide robust support to the side roller, with each side harmoniously coordinating with the frame's guide rail, ensuring smooth operation.
Strategically positioned, four oil cylinders within the frame drive the up-down movement of the side roller bearing block. Sensors ingeniously placed on the side rollers and frame capture every movement, with results promptly displayed on an LCD for easy viewing.
To craft an exquisite cone shape, self-aligning bearings are utilized for both side and lower rollers. With the lower roller level and alignment capable of subtle inclination, fine adjustments allow a snug fit between lower and side rollers, introducing a sophisticated degree of inclination relative to the horizontal plane.
3-4, hydraulic drop end:
The hydraulic drop end device is a critical component, comprising state-of-the-art oil cylinders, precision joints, robust bearing blocks, and more.
The hydraulic drop end system enables effortless and seamless product removal along the Roller shaft, embodying operational excellence.
Once the hydraulic drop operation concludes, whether closure or opening, the oil cylinder's stroke is expertly reset to zero, ready for its next task with precision.The driving force behind this system is a reliable and robust hydraulic station, poised to deliver consistent power.
Balance device:
Step into the future of industrial innovation with our meticulously engineered balance device. This marvel of modern design boasts a compact and groundbreaking structure, guaranteeing top-tier performance when the tipping rack elegantly disengages from the bearing surface of the top roller and embarks on its tipping journey. Harnessing the force of gravity, the top roller's end graciously lowers, while our precision balance device effortlessly maintains equilibrium. Strategically anchored on the fixed side, it creates a thoughtful distance from the fixed frame, secured by sturdy screws, ensuring maximum stability and operational efficiency.
(plate rolling drawing)
Hydraulic System
Discover the epitome of seamless operation with our state-of-the-art hydraulic system. Crafted to perfection, it features a high-precision gear pump, an advanced valve group, and auxiliary pipelines that work in perfect harmony.
The hydraulic valve proudly incorporates the esteemed Yuken superposition series, ensuring that the pipeline layout isengineered with
remarkable simplicity, thus minimizing leakage and enhancing maintenance ease for ultimate efficiency.
The system's architecture is a testament to precision, comprising three distinctive loops: the pressure adjusting loop, synchronization loop, and speed loop, each harmonizing to deliver flawless performance.
The pressure adjusting loop is a masterclass in control, adeptly modulating the system's working pressure through the main overflow valve, reaching a formidable working pressure of 16Mpa.
The synchronization loop exquisitely manages the in-phase movement of the lower roller, utilizing the flow divider and throttle valve for precise speed modulation.
The speed loop is the embodiment of control, expertly managing frame descent, reset operations, and speed adjustments through the throttle valve.
Electric Control System
Our electric control system is a marvel of modern engineering, featuring an integrated electric cabinet, an advanced operation control table, and a portable button box, all operating at 380V/50Hz. Designed with safety in mind, it includes short circuit and overload protection for the main motor and uses an AC contactor to handle positive and reverse rotations. Utilizing PLC programmable control technology, it significantly reduces relay usage, enhancing system stability and durability. Strategically located buttons and indicator lights on the control table ensure a streamlined rolling process, meticulously overseeing every operational detail.
CNC System
Enter the realm of precision with the NC system, designed with a rotational encoder and high-reliability industrial controller to establish a control system that is both consistent and trustworthy.
CNC Function
COur sophisticated NC system elevates the rolling process with its real-time monitoring, seamless data transmission, and a reliable power-off memory function, ensuring continuity and precision.
The industrial control PLC is engineered to automatically inspect the lower position and both ends of the side roller, achieving an impressive synchronization precision of ±0.15mm.
The programmable display provides real-time visibility into the positions of the lower roller and side roller ends, offering
the flexibility to easily configure and set these parameters.
With a displacement transducer resolution of 0.10mm, the display precision reaches an impressive ±0.10mm, setting new standards in measurement 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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