Behold the pinnacle of precision engineering: this is no ordinary machine, it is a cutting-edge four-roller plate rolling phenomenon. The top roller emerges as the centerpiece of this technological masterpiece. It operates as the primary force driver, orchestrating rotational movements with finesse. The lower roller elegantly ascends and descends, expertly guiding the plate and maintaining frictional alignment along its length. Meanwhile, the two side rollers execute a graceful dance, moving up and down at artful angles to impart desired plastic deformation to the steel plate. What sets this machine apart is its adjustable side roller, enabling both symmetric and asymmetrical bending with minimal flat ends. This advantageously surpasses the three-roller systems by negating the need for pre-bending processes and devices while offering preliminary leveling of the steel plate. Industries spanning petroleum, chemical, boiler manufacturing, shipbuilding, hydroelectricity, metal structures, and machinery find it indispensable.
Machine Structural Design:
At the heart of this advanced machinery lies a meticulously crafted structure, comprising the upper roller device with its driving unit, lower roller device:side roller assembly, a sophisticated hydraulic drop end system, an efficient lubrication unit, and robust left and right frames all firmly set upon a durable chassis.
(body frame drawing)
Top Roller and Driving Assembly
The Top Roller Device is an engineering marvel, incorporating the top roller, a hydraulic drop end, fixed bearing, hydraulic motor, and bearing assembly.
Torque is masterfully transferred from the top roller via a connected hydraulic motor, setting the rotation in motion. A meticulously installed protective steel bushing accompanies the hydraulic drop end.
movement. The hydraulic drop end is adeptly equipped with a protective steel bushing, ensuring durability and safety.
Lower Roller and Position Inspection Unit
The Lower Roller Device, a cornerstone of precision, includes the lower roller, an oil cylinder, lower roller bearing, and a self-aligning bearing.
Each sliding bearing block, tasked with the support of the lower roller, aligns seamlessly with the frame's guide rail. It rests on two oil cylinders powered by a sophisticated hydraulic system, facilitating the up-and-down motion of the lower roller. The main oil cylinder exerts a formidable pressure of 16Mpa. Sensors diligently track the distance traversed, presenting data on an LCD. The hydraulic system's adaptable pressure ensures the meticulous application of hydraulic power, achieving the desired rolling force with precision.
(hydraulic drivers drawing)
Side Roller Apparatus
The Side Roller Device is a paragon of intricate design, composed of the side roller's main oil cylinder, self-aligning bearing, among other bearings.
Bearing blocks provide stalwart support to the side roller, with each side seamlessly coordinating with the guiding frame rail.
The side roller bearing block's up-down movement is powered by a network of four strategically placed oil cylinders within the frame. Precision sensors, affixed to the side rollers and frame, gauge the movement and relay measurements to an LCD for clarity.
For the creation of a refined cone shape, self-aligning bearings are utilized for both side and lower rollers. As the lower roller balances and aligns itself to incline, precise adjustments ensure a harmonious fit between lower and side rollers, creating a slight inclination relative to the horizontal axis.
3-4, Hydraulic Drop End
The Hydraulic Drop End Device is an ensemble of oil cylinders, joints, bearing blocks, and additional components, working in a harmonious dance.
The Hydraulic Drop End System facilitates the seamless removal of finished products along the roller shaft, ensuring a fluid workflow.
Upon the hydraulic drop's closure or opening, the oil cylinder stroke is expertly reset to zero, maintaining operational precision.The power source is a trusted hydraulic station, providing reliable energy for uninterrupted operation.
Balance Device
Our balance device is crafted with an innovative compact design, guaranteeing optimal performance. When the tipping rack disengages from the bearing face of the top roller and starts its tipping motion, gravity causes the top roller's end to gracefully descend. This sophisticated balance mechanism is artfully positioned on the fixed side to maintain perfect equilibrium. This strategic placement ensures a calculated distance from the fixed frame and is securely fastened with precision screws, providing unmatched stability and efficiency.
(plate rolling drawing)
Hydraulic System
Our state-of-the-art hydraulic system is a masterpiece of engineering, meticulously crafted with a high-precision gear pump, a sophisticated valve group, and auxiliary pipelines. This design ensures seamless operation and maximized efficiency.
The hydraulic valve incorporates the Yuken superposition series, expertly organized to ensure that the pipeline layoutis
incredibly straightforward. This minimizes the risk of leakage and simplifies maintenance, delivering unprecedented efficiency.
The system architecture is intelligently divided into three distinct loops: the pressure adjusting loop, the synchronization loop, and the speed loop. Each loop plays a vital role in ensuring harmonious and flawless operations.
The pressure adjusting loop meticulously modulates the system's working pressure through the main overflow valve, achieving a robust working pressure of 16Mpa.
The synchronization loop expertly fine-tunes the in-phase movement of the lower roller using a flow divider and throttle valve, allowing for precise speed adjustments tailored to your needs.
The speed loop skillfully controls the descent of the frame, reset operations, and speed adjustments via the throttle valve, ensuring smooth and responsive control.
Electric Control System
Our electric control system is a symphony of advanced technology featuring an integrated electric cabinet, a sophisticated operation control table, and a portable button box, all operating at 380V/50Hz. With built-in short circuit and overload protection for the main motor, it utilizes an AC contactor for deftly managing positive and reverse rotations. Leveraging cutting-edge PLC programmable control technology, it boasts minimal relay usage for enhanced stability and longevity. Strategically arranged buttons and indicator lights on the control table streamline the entire rolling process, overseeing every operational aspect with impeccable precision.
CNC System
Our NC system is ingeniously designed with a rotational encoder and a high-reliability industrial controller, creating a consistent and reliable control framework.
CNC Function
CThis advanced NC system offers real-time monitoring, seamless data transmission, and dependable power-off memory throughout the rolling process, ensuring precision and reliability.
The industrial control PLC automatically inspects the lower position and both ends of the side roller, achieving a synchronization precision of ±0.15mm, ideal for precise applications.
The programmable display provides real-time visibility of the lower roller and side roller end positions, enabling professionals to monitor and adjust with ease.
These parameters can be effortlessly configured and set according to specific requirements.
With a displacement transducer resolution of 0.10mm, the display precision reaches an impressive ±0.10mm, offering unmatched 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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