This advanced machine is a meticulously engineered four-roller plate rolling machine where the top roller serves as the primary drive mechanism. It plays a crucial role in performing the rotation movement. The lower roller executes an up-down motion, enabling the plate to acquire friction along its length. Additionally, the two side rollers perform up-down movements at an angle relative to the straight line. This sophisticated movement allows the steel plate to undergo the essential plastic deformation. By adjusting the side rollers, both symmetric and asymmetric bending can be attained. This results in a theoretically minimal flat end compared to traditional three-roller machines, saving the need for pre-bending procedures and devices. Simultaneously, it offers a rough leveling of the steel plate. Widely implemented across industries such as petroleum, chemical, boiler, shipbuilding, hydroelectricity, metal structure, and machinery.
Machine Construction Overview:
The robust structure of this machine comprises a strategically assembled upper roller device, driving mechanism, lower rollersystem, side roller apparatus, hydraulic drop-end mechanism, lubrication system, left and right frames, chassis, and more.
(Refer to body frame drawing for details)
Top Roller and Driving Device Details:
The top roller device integrates a top roller, hydraulic drop-end, fixed bearings, hydraulic motors, and bearings.
Torque is transmitted to the top roller through a connected hydraulic motor, facilitating the
rotation movement. The hydraulic drop-end comes fitted with a protective steel bushing for added safety.
Lower Roller and Position Inspection Device:
The lower roller assembly includes the lower roller, oil cylinder, and respective bearings, ensuring smooth operation with self-aligning bearings.
Sliding bearing blocks supporting the lower roller align with the frame guide rail. They are mounted on two oil cylinders powered by a hydraulic system, enabling the lower roller's up-down movement. The main oil cylinder operates at a rated pressure of 16Mpa. The motion is monitored by sensors on the lower roller and frame, with outputs visible on an LCD display. The adjustable hydraulic system allows easy alteration of power to meet rolling requirements.
(Refer to hydraulic drivers drawing for further information)
Side Roller Device Configuration:
The side roller system comprises main oil cylinders for side rollers, self-aligning bearings, and support bearings.
Bearing blocks supporting side rollers synchronize with the frame guide rail.
This system enables the side roller bearing blocks to execute up-down movements via four oil cylinders housed within two frames. The vertical displacement of the side rollers is monitored by sensors and displayed on an LCD.
For rolling cone shapes, self-aligning bearings are employed for both side and lower rollers. When the lower roller maintains a level and the line becomes inclined, precise adjustments facilitate a tight closure between the lower and side rollers, accommodating a degree of inclination.
3-4: Hydraulic Drop-End Mechanism:
This device encompasses an oil cylinder, cylinder joints, bearing blocks, and essential components.
The hydraulic drop-end mechanism enables effortless product removal along the roller shaft.
Once the hydraulic drop-end completes its operation, the oil cylinder stroke reaches zero. Power is derived from a dedicated hydraulic station.
Balance Device:
The balance device boasts a sleek and compact design. When the tipping rack slides off the bearing face of the top roller, initiating the tipping motion, the top roller will descend due to gravity. To maintain the top roller's level position, the balance device is strategically placed on the fixed side—outside the fixed side frame. There is a deliberate distance between the fixed frame and the balance device. It is securely attached to the frame using screws, ensuring stability and precision.
(plate rolling drawing)
Hydraulic System
Our hydraulic system is an intricate assembly, composed of a high-efficiency gear pump, a sophisticated valve group, and supportive pipelines, all working in harmony.
The hydraulic valve is part of the premium Yuken superposition hydraulic valve series. The pipeline layout
is designed for simplicity, minimal leakage, and ease of maintenance, ensuring long-lasting performance.
This advanced system consists of three vital loops: the pressure adjusting loop, the synchronization loop, and the speed loop, each catering to specific operational needs.
The pressure adjusting loop fine-tunes the system's working pressure with the main overflow valve, operating efficiently at a working pressure of 16Mpa.
The synchronization loop meticulously adjusts the lower roller's position, moving it up and down in perfect harmony through a flow divider valve. The throttle valve enables fine speed adjustments, ensuring impeccable control.
The speed loop deftly manages the frame's drop and reset functions, controlling the speed with precision through the throttle valve.
Electric Control System
The electric control system is thoughtfully designed and includes an electric cabinet, an operation control table, and a portable button box. Powered at 380V/50Hz, it features a main switch with robust short circuit and overload protection for the main motor. The system's positive and reverse rotations are skillfully managed by an AC contactor. The machine leverages advanced PLC programmable control, minimizing reliance on relays and ensuring stable, long-lasting performance. All essential buttons and indicator lights are ergonomically placed on the control table, offering complete oversight of the rolling process and operational status.
CNC System
Embracing cutting-edge technology, this system utilizes a rotation encoder paired with a highly reliable industry controller, creating a control system renowned for its stability and performance excellence.
CNC Function
CThe NC system excels in real-time monitoring, seamless data transmission, and power-off memory retention throughout the rolling process.
The industry control PLC automatically inspects both the lower position and the two ends of the side roller position, ensuring synchronization precision of an impressive ±0.15mm.
The programmable display provides real-time information on the lower roller position and the two ends of the side roller position, allowing for easy adjustments.
and customizable settings to meet precise requirements.
With a displacement transducer resolution of 0.10mm and a display precision of ±0.10mm, accuracy is guaranteed.
The system features an intelligent automatic self-judge function, enhancing operational efficiency.
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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