This state-of-the-art machine stands as a testament to innovation in steel bending technology. It features a cutting-edge four-roller plate rolling system, with the top roller serving as its pivotal component. It serves as the primary drive, executing smooth rotational movements, while the lower roller adeptly maneuvers with a precise up-and-down motion to elegantly guide the plate, thereby ensuring longitudinal friction alignment. The two side rollers harmoniously ascend and descend at calculated angles, bestowing the desired plastic deformation upon the steel plate. The inclusion of an adjustable side roller enables this machine to perform both symmetric and asymmetrical bending, ensuring a minimal flat end. This feature surpasses traditional three-roller machines by eliminating the necessity for pre-bending steps and auxiliary devices, offering initial-level rough leveling of the steel plate. Its versatility and efficiency make it an essential asset in industries such as petroleum, chemical, boiler manufacturing, shipbuilding, hydroelectricity, metal structures, and machinery.
Machine construction:
The sophisticated design of this machine encompasses critical components such as 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 additional elements.
(body frame drawing)
top roller and driving assembly
The Top roller device is a marvel of engineering, comprising the top roller itself, a hydraulic drop end, fixed bearing, hydraulic motor, and bearing.
Torque is conveyed by the top roller through an integrated hydraulic motor, initiating seamless rotation. A protective steel bushing complements the hydraulic drop end, safeguarding the movement.
movement. The hydraulic drop end is enhanced with a durable protective steel bushing.
lower roller and position inspection unit
The lower roller device is thoughtfully constructed, featuring the lower roller, oil cylinder, lower roller bearing, and a self-aligning bearing.
Each sliding bearing block supporting the lower roller is precisely aligned with the frame guide rail. It is strategically mounted on two oil cylinders, with the hydraulic system empowering the lower roller with precise up-and-down movement. Operating at a rated pressure of 16Mpa, the main oil cylinder ensures optimal performance. Sensors meticulously measure the up-down displacement, displaying real-time data on an LCD. The hydraulic system's adjustable pressure guarantees exact hydraulic power to match the desired rolling force.
(hydraulic drivers drawing)
side roller apparatus
The side roller device is a finely-tuned mechanism, consisting of the side roller's main oil cylinder, self-aligning bearing, and supplementary bearings.
Bearing blocks provide steadfast support for the side roller, ensuring each side seamlessly coordinates with the frame's guide rail.
The side roller bearing block's vertical motion is orchestrated through four strategically positioned oil cylinders within the frame. Sensors affixed to the side rollers and frame facilitate precise movement measurements, with data presented on an LCD.
To achieve a flawlessly crafted cone shape, self-aligning bearings are employed for both the side and lower rollers. As the lower roller becomes inclined, coupled with precise alignment, meticulous adjustments ensure a perfect fit between the lower and side rollers, introducing a subtle inclination relative to the horizontal plane.
3-4, hydraulic drop end
The hydraulic drop end device is composed of oil cylinders, joints, bearing blocks, and auxiliary components.
The hydraulic drop end system enables seamless product removal along the Roller shaft, enhancing operational efficiency.
Upon the completion of hydraulic drop closure or opening procedures, the stroke of the oil cylinder is automatically reset to zero, ensuring readiness for the next operation.The power source is derived from a robust and reliable hydraulic station, ensuring consistent and powerful operation.
Balance device
The balance device has been masterfully engineered with a cutting-edge compact structure, ensuring peak performance when the tipping rack slips off the bearing face of the top roller, initiating the tipping movement. As gravity gracefully guides the top roller’s end downward, this sophisticated balance device maintains equilibrium, being strategically sited on the fixed side. This design creates a precisely calculated distance from the fixed frame, securely fastened by screws, thus assuring unwavering stability and unmatched efficiency.
(plate rolling drawing)
Hydraulic System
Our state-of-the-art hydraulic system is meticulously crafted from a high-precision gear pump, an advanced valve group, along with auxiliary pipelines that enable seamless and elegant operation.
The hydraulic valve employs the Yuken superposition series, ensuring that the pipeline layoutis
remarkably straightforward, significantly minimizing leakage while simplifying maintenance for unmatched operational efficiency.
The system's architecture is composed of three distinct loops: the pressure adjusting loop, synchronization loop, and speed loop, all harmoniously contributing to the system's operation.
The pressure adjusting loop masterfully modulates the system’s working pressure via the main overflow valve, achieving a robust working pressure of 16Mpa.
The synchronization loop fine-tunes the in-phase movement of the lower roller through the flow divider and throttle valve, allowing for precise speed adjustments.
The speed loop expertly governs frame descent, reset operations, and speed adjustments via the throttle valve, ensuring smooth control.
Electric Control System
The electric control system is a paragon of integration, featuring an electric cabinet, a sophisticated operation control table, and a portable button box, all operating at 380V/50Hz. Equipped with both short circuit and overload protection for the main motor, the system utilizes an AC contactor for managing positive and reverse rotations. This system leverages PLC programmable control technology, boasting minimal relay usage for enhanced stability and longevity. Strategically placed buttons and indicator lights on the control table streamline the entire rolling process, overseeing every operational aspect with precision and ease.
CNC System
The NC system is artfully designed with a rotational encoder and high-reliability industrial controller, establishing a consistent and reliable control framework.
CNC Function
CThis sophisticated NC system offers real-time monitoring, seamless data transmission, and reliable power-off memory throughout the rolling process, ensuring optimal performance.
The industrial control PLC automatically inspects the lower position and both ends of the side roller, ensuring a synchronization precision of ±0.15mm.
The programmable display provides real-time visibility of the lower roller and side roller end positions,
and these parameters can be easily configured and set for optimal control.
With a displacement transducer resolution of 0.10mm, the display precision achieves 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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