Introducing our cutting-edge High-Performance Steel Roll Forming Machine with Four Rollers and CNC, a marvel of modern engineering! This state-of-the-art machine boasts a four-roller plate rolling system, with the top roller serving as the pivotal component in the entire operation, ensuring unrivaled precision and efficiency. It serves as the driving force and primary drive mechanism, skillfully performing rotational movements, while the lower roller moves up and down with grace to guide the plate meticulously. This ensures friction aligns lengthwise for impeccable results. The two side rollers perform an elegant dance, moving up and down at an angle, imparting the desired plastic deformation to the steel plate. With the adjustable side roller, this machine achieves both symmetric and asymmetrical bending with finesse, resulting in a minimal flat end. This exquisite feature offers a significant advantage over traditional three-roller machines by eliminating the need for pre-bending procedures and devices, while also providing rough leveling of the steel plate. Its indispensable role spans a myriad of industries, from petroleum and chemical, to boiler manufacturing, shipbuilding, hydroelectricity, and beyond, supporting metal structures and machinery with unparalleled precision.
Machine construction highlights:
At the heart of this advanced machine lies a sophisticated structure, featuring a robust upper roller device and a dynamic driving unit, complemented by a lower roller device crafted with precision,a side roller apparatus, a hydraulic drop end system for seamless operations, a meticulous lubrication unit, and sturdy left and right frames. These components are all securely housed within a durable chassis, ensuring reliability and longevity.
(body frame drawing available for design insights)
Top roller and driving assembly:
The Top roller device is an engineering masterpiece, comprising the top roller, a hydraulic drop end for streamlined operations, fixed bearings, a powerful hydraulic motor, and precision bearings.
The top roller transfers torque effortlessly through an expertly connected hydraulic motor, initiating smooth and efficient rotation. A protective steel bushing is thoughtfully fitted with the hydraulic drop end for enhanced durability.
movement. The inclusion of a protective steel bushing with the hydraulic drop end ensures longevity and reliability in every operation.
Lower roller and position inspection unit:
The lower roller device is meticulously composed of the lower roller, an oil cylinder, lower roller bearings, and a self-aligning bearing for unparalleled stability and precision.
Each sliding bearing block, supporting the lower roller, aligns seamlessly with the frame guide rail, ensuring accurate positioning. These are mounted on two efficient oil cylinders, with the hydraulic system delivering the necessary power for smooth up-down movement of the lower roller. The main oil cylinder operates with a robust rated pressure of 16Mpa. Advanced sensors track the up-down distance with precision, displaying real-time data on an LCD screen. The adjustable hydraulic system ensures precise pressure to meet the desired rolling force, tailoring the operation to your exact specifications.
(hydraulic drivers drawing available for technical reference)
Side roller apparatus:
The side roller device is a work of art, intricately composed of the side roller's main oil cylinder, self-aligning bearings, and additional bearing components, all working harmoniously.
Bearing blocks provide unwavering support to the side roller, with each side perfectly coordinated with the frame's guide rail for smooth and precise movements.
The side roller bearing block's up-down movement is driven with mastery through four strategically placed oil cylinders within the frame. State-of-the-art sensors installed on the side rollers and frame measure every movement with precision, with results displayed clearly on an LCD, allowing for real-time monitoring and adjustments.
To achieve an exquisite cone shape, the use of self-aligning bearings for both side and lower rollers is paramount. As the lower roller level and alignment become inclined, fine adjustments ensure a snug fit between the lower and side rollers, introducing a degree of inclination relative to the horizontal for flawless results.
3-4, Hydraulic drop end system:
The hydraulic drop end device is engineered to perfection, comprising oil cylinders, precision joints, robust bearing blocks, and more, all designed for seamless operation.
The hydraulic drop end system facilitates effortless product removal along the Roller shaft, streamlining the production process and enhancing efficiency.
Upon completion of hydraulic drop closure or opening, the oil cylinder's stroke is reset to zero, ensuring consistency and readiness for the next operation.The power source stems from a reliable, high-performance hydraulic station, delivering consistent and robust energy to keep the system operating at peak performance.
Balance device:
The balance device is expertly engineered with a groundbreaking compact structure, ensuring peak performance when the tipping rack elegantly slips off the bearing face of the top roller, initiating a poised tipping movement. As gravity gracefully causes the top roller's end to descend, this sophisticated balance device meticulously maintains equilibrium, strategically positioned on the fixed side. This thoughtful placement creates a calculated distance from the fixed frame, where it is securely fastened by screws to assure unwavering stability and remarkable efficiency.
(plate rolling drawing)
Hydraulic System
Our cutting-edge hydraulic system is meticulously crafted from a high-precision gear pump, a sophisticated valve group, and auxiliary pipelines, ensuring seamless and flawless operation.
The hydraulic valve incorporates the renowned Yuken superposition series, guaranteeing that the pipeline layoutis
incredibly straightforward, effectively minimizing leakage and simplifying maintenance to offer unparalleled efficiency.
The system architecture is composed of three distinct loops: the pressure adjusting loop, synchronization loop, and speed loop, each meticulously contributing to a harmonious and efficient operation.
The pressure adjusting loop expertly modulates the system's working pressure via the main overflow valve, achieving an impressive robust working pressure of 16Mpa.
The synchronization loop finely tunes the in-phase movement of the lower roller through the flow divider and throttle valve, allowing precise and controlled speed adjustments.
The speed loop masterfully controls frame descent, reset operations, and speed adjustments via the throttle valve, ensuring smooth and efficient operation.
Electric Control System
The electric control system boasts an integrated electric cabinet, a sophisticated operation control table, and a portable button box, all operating at 380V/50Hz. Equipped with robust short circuit and overload protection for the main motor, it utilizes an AC contactor to adeptly manage positive and reverse rotations. The system leverages advanced PLC programmable control technology, minimizing relay usage for enhanced stability and longevity. Strategically positioned 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 meticulously designed with a rotational encoder and a high-reliability industrial controller, establishing a consistent and trustworthy control system.
CNC Function
CThis sophisticated NC system offers real-time monitoring, seamless data transmission, and reliable power-off memory throughout the rolling process, ensuring uninterrupted performance.
The industrial control PLC automatically inspects the lower position and both ends of the side roller, delivering a synchronization precision of an impressive ±0.15mm.
The programmable display provides real-time visibility of the lower roller and side roller end positions,
easily allowing these parameters to be configured and set to your precise specifications.
With a displacement transducer resolution of 0.10mm, the display precision achieves an impressive accuracy of ±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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