Introducing an engineering masterpiece: the Four Rollers Steel Roll Forming Machine. This cutting-edge innovation is expertly crafted for advanced industrial applications, featuring a four-roller plate rolling marvel, where the top roller takes center stage as the essential component. It serves as the primary driver, orchestrating rotational movements with precision, while the lower roller navigates up and down with a refined touch to beautifully guide the plate. This action ensures that friction aligns longitudinally. The two side rollers move gracefully at an angle, conferring the sought-after plastic deformation to the steel plate. With the adaptable side roller, the machine achieves both symmetric and asymmetrical bending, leading to an impressively minimal flat end. It surpasses three-roller machines by eliminating pre-bending steps and devices while offering superior rough leveling of steel plates. This makes it an indispensable asset in the petroleum, chemical, boiler manufacturing, shipbuilding, hydroelectricity, metal structures, and machinery sectors.
Machine construction:
The robust foundation of this sophisticated system is built around the upper roller device and driving unit, lower roller device, side roller apparatus, hydraulic drop end system, lubrication unit, left and right frames, chassis, and more. Its intricate design ensures seamless operation, delivering unrivaled performance.
(body frame drawing)
Top roller and driving assembly
The Top roller device is expertly assembled, featuring the top roller, hydraulic drop end, fixed bearing, hydraulic motor, and bearing.
The top roller distributes torque via the connected hydraulic motor, initiating flawless rotation. A protective steel bushing accompanies the hydraulic drop end.
movement. The hydraulic drop end is fortified with a protective steel bushing for enhanced durability.
Lower roller and position inspection unit
The lower roller device is meticulously constructed, consisting of the lower roller, oil cylinder, lower roller bearing, and a self-aligning bearing.
Each sliding bearing block supports the lower roller, aligning perfectly with the frame guide rail. Mounted on dual oil cylinders, the hydraulic system offers smooth up-down movement power for the lower roller. The core oil cylinder functions at a robust pressure of 16Mpa. Advanced sensors track the up-down distance, displayed on a high-resolution LCD. The hydraulic system's adjustable pressure guarantees precise hydraulic power to fulfill the desired rolling force.
(hydraulic drivers drawing)
Side roller apparatus
The side roller device is intricately engineered with the side roller's main oil cylinder, self-aligning bearing, and accompanying bearings.
The bearing blocks support the side roller, each side coordinating seamlessly with the frame's guide rail for fluid movement.
The up-down movement of the side roller bearing block is empowered by four strategically positioned oil cylinders within the frame. Sensors installed on the side rollers and frame meticulously measure movement, with data presented on an LCD for easy monitoring.
For crafting an exquisite cone shape, self-aligning bearings are employed on both side and lower rollers. As the lower roller levels and alignment inclines, precise adjustments allow a snug fit between lower and side rollers, introducing a refined degree of inclination relative to the horizontal.
3-4, Hydraulic drop end
The hydraulic drop end device features precisely made oil cylinders, joints, bearing blocks, and more.
The hydraulic drop end system facilitates seamless product removal along the Roller shaft, ensuring efficiency and ease of use.
When the hydraulic drop closure or opening is complete, the oil cylinder's stroke resets effortlessly to zero.The reliable power source stems from a robust hydraulic station, ensuring unwavering performance.
Balance device
Our balance device is ingeniously designed with a state-of-the-art compact architecture to ensure optimal functionality. When the tipping rack disengages from the top roller's bearing face, initiating a tipping motion, gravity draws the top roller's end downwards. In this scenario, the advanced balance device plays a crucial role in maintaining equilibrium. It is strategically positioned on the fixed side, creating a calculated gap from the fixed frame, and is securely fastened with screws to guarantee stability and peak efficiency.
(plate rolling drawing)
Hydraulic System
Our cutting-edge hydraulic system is expertly assembled, incorporating a high-precision gear pump, an advanced valve group, and auxiliary pipelines for fluid and seamless operation.
The hydraulic valve utilizes the Yuken superposition series, providing a pipeline layout thatis
exceptionally straightforward, significantly reducing leakage and simplifying maintenance for unparalleled operational efficiency.
The system's architecture is composed of three unique loops: the pressure adjusting loop, synchronization loop, and speed loop, each playing a vital role in achieving harmonious operation.
The pressure adjusting loop regulates the system's working pressure through the main overflow valve, reaching a robust operational pressure of 16Mpa.
The synchronization loop enhances the in-phase movement of the lower roller via the flow divider and throttle valve, facilitating precise speed adjustments.
The speed loop expertly manages frame descent, reset operations, and speed adjustments through the throttle valve for optimal performance.
Electric Control System
Our electric control system is equipped with an integrated electric cabinet, an advanced operation control table, and a portable button box, all operating at 380V/50Hz. It is fortified with short circuit and overload protection for the main motor and utilizes an AC contactor to manage both positive and reverse motor rotations. The system employs PLC programmable control technology, ensuring minimal reliance on relays for enhanced stability and durability. Strategically located buttons along with indicator lights on the control table streamline the rolling process, allowing precise oversight of every operational facet.
CNC System
Our NC system integrates a rotational encoder along with a highly reliable industrial controller, establishing a dependable and consistent control framework.
CNC Function
CThis sophisticated NC system provides real-time monitoring, ensures seamless data transmission, and maintains reliable power-off memory throughout the rolling process.
The industrial control PLC automatically checks the lower position and both ends of the side roller, achieving synchronization precision of ±0.15mm.
The programmable display offers real-time visualization of the positions of the lower roller and side roller ends,
allowing easy configuration and setting of these parameters.
With a displacement transducer resolution of 0.10mm, the display's 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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