W12-20X2000 Four-roller Plate Rolling Machine - Shanghai Shan Chu Industrial Co., Ltd.

Product details

一、Main Overview

The plate rolling process of a plate involves continuous three-point bending of plates. Depending on the rolling temperature, it can be divided into cold rolling, hot rolling and warm rolling. It is a mechanical equipment mainly used to bend metal plates of a certain thickness into cylindrical, arc-shaped, rectangular and other shapes with fixed or variable curvatures, and is one of the essential mechanical equipment in industries including metallurgy, building materials, petroleum, chemical engineering, water conservancy and electric power, bridge construction, military industry, coal, mining, shipbuilding, boiler manufacturing, aviation, and power transmission and transformation equipment manufacturing.
The machine adopts a three-roll symmetrical structure. The top roll moves vertically up and down at the symmetrical central position of the two bottom rolls, with its lifting motion driven by a lead screw, nut and worm drive system. The output gear of the reducer meshes with the gears of the bottom rolls to drive the two bottom rolls to rotate synchronously, supplying torque for plate rolling. The machine features an integrated structure; both the working section and main transmission section are mounted on a rigid welded base, facilitating machine installation and commissioning.

二、Main technical data

No.	Items	Parameters
1	Bending thickness	20mm
2	Max. Bending width	2000mm
3	Roll working length	2050mm
4	Symmetrical Rolling	T20B2000minφ800mm(σs≤245MPa)
5	Asymmetric Rolling(pre-bending)	T16B2000minφ800mm(σs≤245MPa)
6	Upper roller DIA	Ф320mm
7	Lower roller DIA	Ф300mm
8	Side roller DIA	Ф260mm
9	Motor power	15KW
10	Source of power	Hydraulic
11	Driving model of roll	Hydraulic motor and planetary gearbox
12	Operating speed	4.5m/min
13	Voltage and frequenc	380V, 3 phase, 50Hz(can be customized)
14	Max. Working pressure of hydraulic system	19Mpa
15	Control system (CNC controll)	Compatible with CNC automatic and manual control
15	Control system (CNC controll)	Our company's control system is equipped with an automatic rolling program, which can realize one-button operation. It can automatically roll and roll once at a time. It also has data number, storage and recall functions, and can store hundreds of data. Various specifications of automated rolling. The system is compatible with manual operation programs and can be manually operated when needed.

Remarks: 1. Length of remain straight edge≤1.5 times of plate thickness.

2.Bending precision, roundness, linearity, ends surface error all less than 2mm/m.

三、Main structure

1.Drop end cylinder 2.Drop end 3.Left frame 4.Upper roll 5.Side roll 6.Lower roll 7.Right frame 8.Balancing system 9.Upper roll driven device 10.Lower roll driven device 11.Side roll cylinder 12.Lower roll cylinder 13.Bottom frame 14.Side support system【optional】 15.Top support system【optional】 16. Electric feeding electric roll【optional】 17.Hydraulic system 18.Electronic control system

1) The working roll

One of the most important components of the rolling machine, its quality and performance has a direct impact on the service life of the rolling machine and the precision of rolling.

(1) Material of working roll

Working rolls are made of high-strength high-quality steel 42CrMo material, after forging, roughing, quenching and tempering, HB240 ~ 300, finishing after the intermediate frequency quenching HRC47-58, according to JB/ZG4289-86 roll steel standards, the stiffness is consistent (1/700 ~1/1000) L. L------The distance between the centerlines of the sides rack. And strictly in accordance with the working process of manufacturing all the standard roll manufacturing, to ensure its comprehensive mechanical properties.

(Upper Roller Device)The picture is for reference only

(2) Working Roll Rotation

Working Roll Rotation: Hydraulic Motor > Planetary Gearbox > Working Roll

(Lower roller and horizontal moving device) The picture is for reference only

The upper roll is a driving roll of four roll rolling machine (as shown below). The independent hydraulic motor on the upper roll and the high-power box are directly coupled(straight), not through the intermediate gear transmission, which is the most energy-saving drive method. The hydraulic motor is equipped with an immediate brake to allow the roll to stop accurately in the pre-bending state.

(Roller device) The picture is for reference only

(3) Working roll movement

According to the movement method of the working roll (side roller) of the rolling machine, the linear slide technology is adopted. The oil cylinder adopts an inverted oil cylinder, which greatly increases the contact area between the slider and the slide rail, and improves the stability and the rolling precision of the machine tool.

2) Bearing at both ends of the working roll

(Main Drive Unit) The picture is for reference only

The four-roll rolling machine adopts very durable double-row self-aligning roller bearings recommended by the industry for each roller.

3)Rack and base

The base and frame are the main parts of the equipment. Our company selects high-quality steel, uses CNC cutting, grinding and welding, and then sends the welded structural parts to the professional heat treatment factory for stress relief annealing—CNC lathe machining eliminating welding stress, so that it has enough strength and stiffness, to ensure normal operation at full load. All records of the workpiece are included in the quality tracking system.

4) Hydraulic system

Each oil circuit is routed with two relief valve to control pressures. The maximum set pressure for each oil circuit is 25 MPa, which is mainly to control the main cylinder pressure, and the other relief valve is set to 16 MPa, mainly to control the overturning cylinder and balancing cylinder pressure.

In order to ensure the synchronization accuracy of the main oil cylinders at both ends of each moving working roll, high-precision displacement sensors are installed on the left and right racks and the tilting frames. Through the pressure sensors, the microcomputer control system detects and adjusts the movements of the main oil cylinder pistons to achieve the precison of the both working roll ends.

Advantage of our hydraulic system:

a. The unique pre-discharge technology is adopted to effectively avoid hydraulic shock and improve the life of the pipeline and seal.

b. The hydraulic components are selected YUKEN quality products to ensure the stability of the hydraulic system.

c. Each input and output port of the hydraulic system is provided with corresponding detection points, which are convenient for maintenance and fault checking. The oil pump adopts a lower-mounted type and positive pressure oil absorption. At the same time, the filters, level gauges, and all transmitting devices can automatically warn of faults.

d. The system is manufactured strictly in accordding to national standards and industry standards. The radius of the tube is reasonable, and the radius is not less than 90°. The transition is smooth and the damper tube clamps are properly arranged, which effectively avoids shock and vibration. Make surethat there is no shock or vibration in the hydraulic circuit.

e. The system design fully considers the high efficiency and energy saving, reduces the power waste, and reduces the heat source.

f. The hydraulic oil pump and motor set are equipped with a special shock absorbing pad, and the oil suction port is equipped with a shock absorbing throat.

g. Provide the test report of the main oil cylinder. System production strictly perform the national standards, and the proper connection point adopts a special sealant. Avoid leakage.

h. Provide common fault phenomena and elimination methods for the hydraulic system of rolling machine.

i. To ensure the manufacturing quality of the hydraulic system, the system is manufactured according to hydraulic professional manufacturers and the national GB3766-83 "General technical conditions for hydraulic systems."

Gripping pressure can be set:

For different product rolling process requirements, the clamping force between the upper and lower rolls can be set in advance to effectively prevent excessive pressure on the softer material.

The clamping force is controlled by the hydraulic station relief valve.

5) Hydraulic system(CNC control system)

1. The micro-control system includes the main electrical cabinets, control cabinets and other hardware components and special control software.

2. Main Specifications:

Display accuracy: ≤±0.05mm

When the lower roll is lifted and the side roll is inclined and lifted and the displacement is synchronously controlled, the synchronization accuracy is: ≤±0.1mm

Sensor displacement resolution: ≤0.05mm

3. The core components of the micro-control system

(Tipping Device) The picture is for reference only

4. CNC control system(optional)

Our company's control system is equipped with an automatic rolling program, which can realize one-button operation. It can automatically roll and roll once at a time. It also has data number, storage and recall functions, and can store hundreds of data. Various specifications of automated rolling. The system is compatible with manual operation programs and can be manually operated when needed.

6) The processes of rolling board

(Chassis) The picture is for reference only

7) Main configuration

No.	Accessory name	Brand	Number
1	Working roller	Nangang	4 piece
2	Hydraulic valves	Yuken,Japan/JINHAI	1 set
3	Hydraulic pump	Changyuan,Hefei	1 set
4	Main sealing ring	CARCO from Italy or NOK from Japan	1 set
5	Working roller bearing	Wafangdian	1 set
6	Motion detector	OMRON,Japan/BRSEN	1 set
7	Touching screen	Siemens/MCGS	1 piece
8	PLC programmable logic controller	Siemens/MCGS	1 piece
9	Rotary encoder	REP,Taiwan/BRSEN	1 set
10	Planetary reducer	Peika,Ningbo	1 set
11	Main motor	Tongde	1 set

8) List of accessories to be provided by us

No.	Item	Quantity	Unit
1	Main machine	1	set
2	Hydraulic station	1	set
3	Electrical control counter	1	set
4	Foundation drawing	1	copy
5	Operation Manual	1	copy
6	Certificate of Quality	1	copy
7	Packing List	1	copy
8	Foundation bolt	1	set
9	Oil Gun	1	piece
10	O ring	1	set
11	Electrical cabinet key	1	piece
12	Circuit diagram	1	copy
13	Hydraulic schematic	1	copy

一、Main Overview

二、Main technical data

No.	Items	Parameters
1	Bending thickness	20mm
2	Max. Bending width	2000mm
3	Roll working length	2050mm
4	Symmetrical Rolling	T20B2000minφ800mm(σs≤245MPa)
5	Asymmetric Rolling(pre-bending)	T16B2000minφ800mm(σs≤245MPa)
6	Upper roller DIA	Ф320mm
7	Lower roller DIA	Ф300mm
8	Side roller DIA	Ф260mm
9	Motor power	15KW
10	Source of power	Hydraulic
11	Driving model of roll	Hydraulic motor and planetary gearbox
12	Operating speed	4.5m/min
13	Voltage and frequenc	380V, 3 phase, 50Hz(can be customized)
14	Max. Working pressure of hydraulic system	19Mpa
15	Control system (CNC controll)	Compatible with CNC automatic and manual control
15	Control system (CNC controll)	Our company's control system is equipped with an automatic rolling program, which can realize one-button operation. It can automatically roll and roll once at a time. It also has data number, storage and recall functions, and can store hundreds of data. Various specifications of automated rolling. The system is compatible with manual operation programs and can be manually operated when needed.

Remarks: 1. Length of remain straight edge≤1.5 times of plate thickness.

2.Bending precision, roundness, linearity, ends surface error all less than 2mm/m.

三、Main structure

1) The working roll

One of the most important components of the rolling machine, its quality and performance has a direct impact on the service life of the rolling machine and the precision of rolling.

(1) Material of working roll

(Upper Roller Device)The picture is for reference only

(2) Working Roll Rotation

Working Roll Rotation: Hydraulic Motor > Planetary Gearbox > Working Roll

(Lower roller and horizontal moving device) The picture is for reference only

(Roller device) The picture is for reference only

(3) Working roll movement

2) Bearing at both ends of the working roll

(Main Drive Unit) The picture is for reference only

The four-roll rolling machine adopts very durable double-row self-aligning roller bearings recommended by the industry for each roller.

3)Rack and base

4) Hydraulic system

Advantage of our hydraulic system:

a. The unique pre-discharge technology is adopted to effectively avoid hydraulic shock and improve the life of the pipeline and seal.

b. The hydraulic components are selected YUKEN quality products to ensure the stability of the hydraulic system.

e. The system design fully considers the high efficiency and energy saving, reduces the power waste, and reduces the heat source.

f. The hydraulic oil pump and motor set are equipped with a special shock absorbing pad, and the oil suction port is equipped with a shock absorbing throat.

g. Provide the test report of the main oil cylinder. System production strictly perform the national standards, and the proper connection point adopts a special sealant. Avoid leakage.

h. Provide common fault phenomena and elimination methods for the hydraulic system of rolling machine.

Gripping pressure can be set:

For different product rolling process requirements, the clamping force between the upper and lower rolls can be set in advance to effectively prevent excessive pressure on the softer material.

The clamping force is controlled by the hydraulic station relief valve.

5) Hydraulic system(CNC control system)

1. The micro-control system includes the main electrical cabinets, control cabinets and other hardware components and special control software.

2. Main Specifications:

Display accuracy: ≤±0.05mm

When the lower roll is lifted and the side roll is inclined and lifted and the displacement is synchronously controlled, the synchronization accuracy is: ≤±0.1mm

Sensor displacement resolution: ≤0.05mm

3. The core components of the micro-control system

(Tipping Device) The picture is for reference only

(Chassis) The picture is for reference only

四、Hydraulic system

The machine adopts an independent oil circuit system design with two functional sections. The first is the main transmission section, which supplies power to the top work roll; the second is the auxiliary transmission section, which provides power for the turnover of the winding head. A stacked valve structure is adopted, featuring the following advantages:

1. It reduces the space occupied by equipment and installation;

2. Specialized installation skills are not required, and the hydraulic system can be expanded or modified quickly and conveniently;

3. It eliminates the use of flow divider-combiner valve synchronization systems that are susceptible to inconsistent pressures between two cylinders, resolves issues such as leakage, vibration and noise caused by pipeline connections, and improves the reliability of the hydraulic system;

4. Composed of stacked modular components, the system facilitates maintenance and inspection.

Each oil circuit is equipped with two relief valves for pressure regulation. The maximum set pressure of each oil circuit is 25 MPa, which mainly controls the pressure of the main cylinder. The other relief valve is set at 16 MPa to regulate the pressure of the turnover cylinder and balance cylinder. The main cylinder in each oil circuit consists of two sets of stacked components to adjust the movement speed of the main cylinder, matching the operating speed requirements of the top roll under various working conditions. Proprietary pre-pressure relief technology is applied to effectively prevent hydraulic shock and extend the service life of pipelines and seals.

b. High-quality hydraulic components are selected to guarantee the stability of the hydraulic system.

c. Corresponding test points are installed at all input and output ports of the hydraulic system to facilitate maintenance and fault diagnosis.

d. The system is manufactured in strict compliance with national and industrial standards. Pipeline bends feature a reasonable radius of no less than 90° with smooth transitions. Vibration-damping pipe clamps are arranged properly to effectively suppress hydraulic shock and mechanical vibration, ensuring shock-free and vibration-free operation of hydraulic pipelines.

e. The system design fully prioritizes high efficiency and energy conservation to minimize power waste and heat generation sources.

五、Electrical Control System

1. The electrical control system consists of hardware components including the main electrical cabinet and dedicated control software.

2. The system is equipped with two operating modes, namely touch screen control and manual control, which can be switched conveniently.

Sensors are products of well-known brands to guarantee positioning accuracy and realize position monitoring of work rolls.

3. Main technical indicators:

Mean Time Between Failures (MTBF): ≥20,000 hours

Display accuracy: ≤±0.2 mm

Synchronization accuracy during synchronous displacement control for lower roll lifting and side roll tilting lifting: ≤±0.2 mm

Sensor displacement resolution: ≤0.1 mm

4. PLC Control Principle:

The upper roller universal consists of a Programmable Logic Controller (PLC), its digital and analog expansion modules, peripheral circuits, displacement sensors and other components.

The touch screen communicates with the PLC via a dedicated communication cable to acquire data including upper roller displacement, data of balance cylinders and tilting cylinders, as well as the input and output status of the PLC.

The touch screen and the PLC integrate all the above information and conduct intelligent processing to control the PLC output signals. Through intermediate relays, the peripheral electrical equipment is controlled to adjust motor operation and hydraulic valve switching, so as to ensure the normal operation of the control system and maintain its operating accuracy. Meanwhile, the control system displays various data and information such as displacement, alarms and output status on the screen in a combination of graphics and texts.

Control System Functions: The PLC system can display a variety of real-time data and plate bending information.

This system features advanced design, favorable operability, safe and stable operation and excellent fault tolerance, with the following functions.

Real-time display of the absolute positions of both ends of the top roller, as well as soft and hard limit protection functions for all moving components; fault self-diagnosis display and intelligent judgment function for operational errors

Power-off memory function: If the position of the work roller changes for some reason after an unexpected power cut during operation or complete machine shutdown upon completion of plate rolling, the PLC system will automatically track and accurately display the actual position once power is restored.

Safety protection function: In case of emergencies, operators can quickly and conveniently shut down the equipment and system to guarantee the safety of both equipment and personnel.

Control functions:

The touch screen communicates with the programmable logic controller (PLC) via a dedicated communication cable to acquire data including four displacement values (up, down, left and right) of the work roller and PLC input/output status. It integrates all the above data with the PLC and conducts intelligent processing to control PLC outputs. Through intermediate relays, peripheral electrical appliances are regulated to control motor operation and hydraulic valve switching, thereby realizing normal operation of the control system.

The picture is for reference only

六、Coil Plate Process Flow Chart

Plan 1:

The picture is for reference only

Plan Two:

The picture is for reference only

七、Technical Features of Three-Roll Universal Bending Machine

7-1. Convex Top Roll with Supporting Roll Adjustment Beneath Bottom Rolls for High Straightness of Workpieces The supporting rolls installed under the bottom rolls are adjustable to precisely control the straightness of finished products, which significantly improves the linearity of workpieces.
7-2. Rear Bending Rolling for High Roundness of Workpieces Convex top rolls are adopted. The preset crown of the top roll is generally set to 70% of the uniformly distributed load on the roll. The bottom rolls feature a relatively small diameter and are supported by vertically adjustable supporting rolls underneath.Based on the load of rolled workpieces, the three-roll universal bending machine applies rear bending (the feeding direction of the plate is opposite to the moving direction of the top roll). While the top roll descends, the bottom rolls rotate to realize continuous bending. The plate ends can be pre-bent under direct pressure, eliminating rear angles caused by front bending. In addition, the length and shape of residual straight edges can be controlled.

In contrast, asymmetric three-roll machines usually adopt front bending. Operators need to pre-bend both ends of the plate first and then perform symmetrical rolling for forming. This mode requires skilled operators, tends to create rear angles on workpieces, and makes it difficult to control the shape of residual straight edges.

7-3. Measures to Reduce Edge Offset of Workpieces

The three-roll universal bending machine adopts the following solutions to lower the edge offset of finished products:

1. Control the dimensional accuracy and geometric tolerance of the center distance between the two bottom rolls as a key process;

2. Adopt electro-hydraulic synchronization of the top roll equipped with a feedback system for automatic leveling.

The stroke of the top roll hydraulic cylinder is detected by a rotary encoder and compared by the controller. High and low electrical signals are transmitted to the programmable logic controller (PLC), which controls the electromagnets of the electromagnetic directional valves at both ends of the top roll through continuous feedback and comparison.

八、List of Main Components

Names of Main Components	Remarks
top roll	Hardness HRC45-55
lower roll	Hardness HRC45-55
bed base	Welded structural parts
Tipping Device	Welded structural parts
oil cylinder	finished product
Transmission system	Motor + Reducer + Gear
Hydraulic system	Yuci, Shanxi / Yuci Hongtai / Well-known Domestic Brand
Control system	OMRON / Well-known domestic brand

九、List of Purchased & Outsourced Components

Serial Number	Name of Goods	Manufacturer and Description	quantity
1	Main motor	Jiangsu Yingkai / Well-known domestic brand	1 set
2	Main Reducer	Taixing, Jiangsu / Well-known domestic brand	1 set
3	Rotary Encoder	Ripu Avago from Taiwan / Well-known domestic brand	1 set
4	PLC System	OMRON/Hexin/well-known domestic brands	1 piece
5	Touch screen	Xinje from Wuxi / Well-known domestic brand	1 piece
6	Micro Relay	Siemens / well-known domestic brands	1 set
7	Work roll bearing	ZWZ Wafangdian Bearing / Well-known Domestic Brand	1 set
8	Master cylinder seal	Italy's "CARCO"/ Well-known domestic brand	1 set