This state-of-the-art machine is a four-roller plate rolling marvel, with the top roller as the key component. It serves as the primary drive, performing rotational movements, while the lower roller moves up and down to elegantly guide the plate, ensuring friction aligns lengthwise. The two side rollers gracefully move up and down at an angle, imparting the desired plastic deformation to the steel plate. Thanks to the adjustable side roller, this machine achieves both symmetric and asymmetrical bending, resulting in a minimal flat end, offering an advantage over three-roller machines by eliminating the need for pre-bending procedures and devices, and providing rough leveling of the steel plate. This makes it indispensable in industries such as petroleum, chemical, boiler manufacturing, shipbuilding, hydroelectricity, metal structures, and machinery.
Machine construction:
The core structure of this sophisticated machine includes 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.
(body frame drawing)
top roller and driving assembly
The Top roller device comprises the top roller, a hydraulic drop end, fixed bearing, hydraulic motor, and bearing.
The top roller transfers torque through a connected hydraulic motor, initiating rotation. A protective steel bushing is fitted with the hydraulic drop end.
movement. The hydraulic drop end comes equipped with a protective steel bushing.
lower roller and position inspection unit
The lower roller device consists of the lower roller, oil cylinder, lower roller bearing, and a self-aligning bearing.
Each sliding bearing block, supporting the lower roller, aligns with the frame guide rail. It is mounted on two oil cylinders, with the hydraulic system providing up-down movement power for the lower roller. The main oil cylinder operates at a rated pressure of 16Mpa. Sensors track the up-down distance, displaying it on an LCD. The hydraulic system's adjustable pressure ensures precise hydraulic power to meet desired rolling force.
(hydraulic drivers drawing)
side roller apparatus
The side roller device is intricately composed of the side roller's main oil cylinder, self-aligning bearing, and other bearings.
Bearing blocks support the side roller, with each side coordinating seamlessly with the frame's guide rail.
The side roller bearing block's up-down movement is driven through four strategically placed oil cylinders within the frame. Sensors installed on the side rollers and frame measure the movement, with results displayed on an LCD.
To achieve an exquisite cone shape, self-aligning bearings are employed for both side and lower rollers. With the lower roller level and alignment becoming inclined, fine adjustments enable a snug fit between lower and side rollers, introducing a degree of inclination relative to the horizontal.
3-4, hydraulic drop end
The hydraulic drop end device comprises oil cylinders, joints, bearing blocks, and more.
The hydraulic drop end system facilitates effortless product removal along the Roller shaft.
Upon completion of hydraulic drop closure or opening, the oil cylinder's stroke is reset to zero. The power source stems from a reliable hydraulic station.
Balance device
The balance device is engineered with an innovative compact structure, ensuring optimal performance when the tipping rack slips off the bearing face of the top roller and initiates tipping movement. As gravity causes the top roller’s end to descend, this sophisticated balance device maintains equilibrium by being strategically positioned on the fixed side. This placement creates a calculated distance from the fixed frame, securely fastened by screws to assure stability and efficiency.
(plate rolling drawing)
Hydraulic System
Our advanced hydraulic system is meticulously crafted from a high-precision gear pump, a sophisticated valve group, and auxiliary pipelines for seamless operation.
The hydraulic valve employs the Yuken superposition series, ensuring the pipeline layout is
remarkably straightforward, minimizing leakage and simplifying maintenance for unparalleled efficiency.
The system architecture comprises three distinct loops: the pressure adjusting loop, synchronization loop, and speed loop, each contributing to a harmonious operation.
The pressure adjusting loop 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 precise speed adjustments.
The speed loop expertly controls frame descent, reset operations, and speed adjustments via the throttle valve.
Electric Control System
The electric control system features an integrated electric cabinet, a sophisticated operation control table, and a portable button box, operating at 380V/50Hz. Equipped with short circuit and overload protection for the main motor, it utilizes an AC contactor for managing positive and reverse rotations. The 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.
CNC System
The NC system is designed with a rotational encoder and high-reliability industrial controller, establishing a consistent and reliable control system.
CNC Function
CThis sophisticated NC system offers real-time monitoring, seamless data transmission, and reliable power-off memory throughout the rolling process.
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.
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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