This state-of-the-art machine epitomizes innovation and efficiency, a four-roller plate rolling marvel where the top roller emerges as the central component, steering the journey to perfection. It serves as the primary drive, orchestrating rotational movements, with the lower roller seamlessly gliding up and down to gracefully guide the plate, ensuring friction aligns lengthwise with precision. The two side rollers enhance the experience by moving up and down at a tailored angle, imparting the desired plastic deformation to the steel plate masterfully. Thanks to the adjustable side roller, this machine achieves both symmetric and asymmetrical bending, resulting in an impressively minimal flat end. It boasts superiority over three-roller machines by eliminating the necessity for pre-bending procedures and additional devices, while also providing a rough leveling of the steel plate. This makes it a cornerstone in industries such as petroleum, chemical, boiler manufacturing, shipbuilding, hydroelectricity, metal structures, and machinery, setting a new standard of excellence.
Machine construction:
The core structure of this sophisticated machine includes a robust upper roller device and driving unit, alongside a lower roller device, side roller apparatus, hydraulic drop end system, a responsive lubrication unit, left and right frames, a sturdy chassis, and more, creating a symphony of engineering excellence.
(body frame drawing)
top roller and driving assembly
The Top roller device comprises an intricate assembly of the top roller, a hydraulic drop end, fixed bearing, hydraulic motor, and bearing, working in harmony.
The top roller transfers torque effortlessly through a connected hydraulic motor, initiating rotation with finesse. A protective steel bushing is adeptly fitted with the hydraulic drop end, ensuring seamless
movement. The hydraulic drop end elevates sophistication, being equipped with a protective steel bushing that guarantees longevity and resilience.
lower roller and position inspection unit
The lower roller device is composed of the lower roller, oil cylinder, a lower roller bearing, and a self-aligning bearing, each playing a pivotal role.
Each sliding bearing block, supporting the lower roller, aligns precisely with the frame guide rail. It is mounted on two robust oil cylinders, empowered by a hydraulic system that provides the up-down movement power with authority. Operating at a rated pressure of 16Mpa, the main oil cylinder is a testament to reliability. Sensors meticulously track the up-down distance, displaying it on an intuitive LCD. The hydraulic system's adjustable pressure ensures precise hydraulic power to meet all desired rolling force requirements, offering unparalleled control.
(hydraulic drivers drawing)
side roller apparatus
The side roller device is a masterful construction, intricately composed of the side roller's main oil cylinder, self-aligning bearing, and other bearings, each integral to its operation.
Bearing blocks support the side roller with unwavering strength, each side coordinating seamlessly with the frame's guide rail, ensuring smooth, precise operation.
The side roller bearing block's up-down movement is driven with precision through four strategically positioned oil cylinders within the frame. Sensors, installed on the side rollers and frame, measure the movement meticulously, with results displayed on a clear LCD, providing real-time data.
To achieve an exquisite cone shape, self-aligning bearings are employed for both side and lower rollers. As the lower roller level and alignment become inclined, fine adjustments enable a snug, precise fit between the lower and side rollers, introducing the perfect degree of inclination relative to the horizontal, crafting perfection.
3-4, hydraulic drop end
The hydraulic drop end device is a sophisticated assembly comprising oil cylinders, joints, bearing blocks, and more, working in perfect harmony.
The hydraulic drop end system facilitates the effortless and seamless removal of the product along the Roller shaft, enhancing productivity.
Upon completion of the hydraulic drop closure or opening, the oil cylinder's stroke is efficiently reset to zero, ensuring readiness for the next operation.The power source is a reliable hydraulic station, providing consistent, dependable energy.
Balance device
Our revolutionary balance device is crafted with an ingeniously compact design to ensure flawless performance. When the tipping rack shifts off the bearing face of the top roller, and starts the tipping movement, its gravity-driven descent is expertly counterbalanced by this state-of-the-art device. Strategically placed on the fixed side, the balance device is positioned just the right distance from the fixed frame, and is securely fastened by screws. This ensures unwavering stability, ultimate efficiency, and the perfect equilibrium of the entire system.
(plate rolling drawing)
Hydraulic System
Our cutting-edge hydraulic system is a masterpiece of engineering, meticulously assembled from a precision-crafted gear pump, a sophisticated valve group, and auxiliary pipelines for seamless and impeccable operation.
The hydraulic valve utilizes the renowned Yuken superposition series, which ensures that the pipeline layoutis
astoundingly straightforward, reducing leakage possibilities and simplifying maintenance. This guarantees unparalleled operational efficiency.
The system showcases three distinct loops: the pressure adjusting loop, synchronization loop, and speed loop, each contributing to flawless and harmonious operation.
The pressure adjusting loop deftly modulates the system’s working pressure through the main overflow valve, achieving a formidable working pressure of 16Mpa.
The synchronization loop skillfully fine-tunes the synchronized movement of the lower roller using the flow divider and throttle valve, allowing for precise speed adjustments.
The speed loop expertly controls frame descent, reset functions, and speed adjustments via the throttle valve, ensuring smooth and efficient operation.
Electric Control System
Our electric control system is an epitome of modern technology, featuring an integrated electric cabinet, a sophisticated operation control table, and a portable button box operating at 380V/50Hz. It is endowed with short circuit and overload protection for the main motor, using an AC contactor for managing both positive and reverse rotations. The system incorporates PLC programmable control technology with minimal relay usage, ensuring enhanced stability and prolonged longevity. The strategically designed control table, equipped with intuitive buttons and indicator lights, streamlines the entire rolling process, overseeing every facet of operation with unparalleled precision and efficiency.
CNC System
Our NC system is brilliantly engineered with a rotational encoder and a high-reliability industrial controller, establishing a consistent and dependable control framework.
CNC Function
CThis cutting-edge NC system offers real-time monitoring, impeccable data transmission, and steadfast power-off memory throughout the rolling process, ensuring a seamless operation.
The industrial control PLC performs automatic inspections of the lower position and both side roller ends, maintaining synchronization precision of ±0.15mm, a testament to its superior accuracy.
The programmable display provides real-time insights into the positions of the lower roller and side roller ends,
and these parameters are effortlessly configured and adjustable to meet specific requirements.
With a displacement transducer resolution of 0.10mm, the display precision achieves an exceptional ±0.10mm, showcasing its advanced technological capabilities.
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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