Precision Upper Roller Plate Bending Machine for Cold Roll Forming

Product Description

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

This machine is four-roller plate rolling machine, top roller is the main drive and do rotation movement, lower roller makes up-down movement to make the plate  can get the frication along with length direction, two side rollers makes Up-down movement which is an angel with straight line, which can make the steel plate get the needed plastic deformation. Because adjust the side roller can achieve symmetric bending and asymmetrical bending, the flat end will be very short in theory, comparing with three-roller plate rolling machine, which can save pre-bending procedure and pre-bending device, meanwhile it can make rough leveling of steel plate. It is extensively applied in petroleum industry, chemical industry, boiler, shipbuilding industry, hydroelectricity, metal structure and machinery industry.

Detailed Photos

 

Machine construction:
The main body structure of the machine is composed of upper roller device and driving device, lower roller device, side roller device, hydraulic drop end device, lubrication device, Left and right frame, chassis and etc.



(body frame drawing)
top roller and driving device
Top roller device is composed of top roller, hydraulic drop end, fixed bearing, hydraulic motor and bearing.
Top roller pass the torque through connecting hydraulic motor and top roller makes
rotation movement. Hydraulic drop end is installed with protection steel bushing.


lower roller and position inspection device
Lower roller device is composed of lower roller, oil cylinder, bearing of lower roller, self-aligning bearing.
The two side of sliding bearing block (which supports lower roller) coordinate with frame guide rail. Underside is fixed on the two oil cylinder, hydraulic system offer power for up-down movement of lower roller. The rated pressure for main oil cylinder is 16Mpa.The up-down distance is inspected by sensor installed on the lower roller and frame and displayed by LCD. Because the pressure of hydraulic system can be adjusted freely, it can get needed hydraulic power easily according to the needed rolling power.

(hydraulic drivers drawing)

side roller device
The side roller device is composed of main oil cylinder of side roller, self-aligning bearing and bearing.
The bearing block support the side roller and the two side of bearing block coordinate with frame guide rail.
Side roller drives side roller bearing block makes up-down movement through four oil cylinders which are installed in the inside of two frames. The up-down distance of two side rollers is inspected by sensor installed on the side roller and frame and displayed by LCD.
To roll cone shape, we use self-aligning bearing for both side roller and lower roller, when the lower roller keep level and when the horizontal line become slope line, lower roller and side rollers can close tightly through fine adjusting; there is a degree of inclination between horizontal line and lower roller & side roller.
3-4,hydraulic drop end
Hydraulic drop end device is composed of oil cylinder, oil cylinder joint, bearing block, oil cylinder bearing and etc.
The hydraulic drop end device is easy to take out the product along Roller shaft.
When the hydraulic drop finishes closing or opening, the stroke of oil cylinder is zero. The power comes from hydraulic station.
Balance device
Balance device adopts compact structure, when the tipping rack slip off bearing face of top roller and make tipping movement, this end of top roller will drop due to gravity. To make the top roller keep level, the balance device is installed on the fixed side (out of fixed side frame, namely there is a distance between fixed frame and balance device) and meanwhile it is fixed on the frame by screws.

(plate rolling drawing)
Hydraulic system
Hydraulic system is composed of gear pump, valve group and assistant pipelines.
Hydraulic valve adopts Yuken superposition hydraulic valve series, the pipeline lay out
is simple, few leakage and easy for maintain.
The system is made up of three loop, pressure adjusting loop, synchronization loop and speed loop.
The pressure adjusting loop adjusts the system working pressure through main overflow valve. The system working pressure is 16Mpa
Synchronization loop can adjust lower roller up and down in-phase through flow divider valve and throttle valve and throttle valve can make fine adjust speed up, down.
Speed loop control frames drop and reset and adjust the speed through throttle valve.

Electric control system

The electric control system is made up of electric cabinet, operation control table, portable button box. The power is 380V/50Hz.The main switch has short circuit protection and over-loading protection of main motor. The positive rotation and reverse rotation are controlled by AC contactor; the machine adopts PLC programmable control, which is with few relay, stable and long working life. All the buttons and instruction lights for completing the whole rolling process are on the control table, which can control the whole operation process and working status.

CNC system

The system adopts rotation encoder, matching with high reliability industry controller, which builds up a control system of stable performance.
CNC function
CNC system is of real time monitoring,data pass and power off memory during the process of rolling.
Industry control PLC will inspect the lower position and two end of side roller position automatically and control it to ensure synchronization precision  ±0.15mm
Programmable display shows real time lower roller position and two end of side roller
position and it can be set.
Displacement transducer resolution is 0.10mm, display precision is ±0.10mm
Automatic Self-judge function