Jsyzsk1 China-Origin CNC Machinery roll forming machine manufacturers
The W11NC series Marine Plate Rolling Machine is your ultimate solution for crafting circular plates, such as ship shells and pressing groove type bulkheads, with unmatched precision. Designed to meet diverse customer needs, it can be configured as a symmetrical or asymmetrical three-roll coiling machine. The machine boasts a rigid beam above the upper roller, complemented by multiple sets of rollers positioned between the upper roller, the beam, and the lower roller. This innovative design significantly enhances the stiffness and durability of both the upper and lower rollers, ensuring optimal performance. Experience the power of three rollers with full drive, engineered for superior efficiency and reliability in marine plate rolling applications.
| name |
unit |
Parameter value |
Remark |
| W11STNC- 30 X 30 00 |
W11STNC - 100X3000 _ _ |
W11STNC-150X3000 |
rolled sheet
bow to extremes |
MPa |
≤245 |
≤245 |
≤245 |
|
| Full load coil thickness |
mm |
30 |
100 |
150 |
|
| Full load pre-bent plate thickness |
mm |
twenty four |
80 |
120 |
|
| Maximum coil width |
mm |
3000 |
3000 |
3000 |
|
| Remaining straight edge length |
mm |
≤2-2.5 times plate thickness |
|
| Rolling speed |
m/min |
0-6 |
|
| Work roll material |
/ |
42CrMo |
|
| Work roll drive |
/ |
Hydraulic motor + reducer drive/electric motor + reducer drive |
|
| Work roll movement |
/ |
Upper roller lifting hydraulic drive, translation hydraulic/mechanical drive |
|
| Hydraulic system pressure |
MPa |
25 |
|
| Lubrication system |
/ |
Automatic lubrication at startup |
|
| Operation method |
/ |
Portable wireless remote control and drag line mobile operating platform |
interlock |
| Feeding roller |
/ |
Fully driven feeding roller table and centering device |
Optional |
| Front and rear support |
/ |
Hydraulic lift (can be used as a feed transition roller when lowered) |
Optional |
| Correction device |
/ |
Hydraulic correction device to correct axial misalignment |
Optional |
| top support |
/ |
Rolling cone auxiliary support mechanism |
Optional |
| Note: It can be customized according to the buyer's plate yield (Mpa), plate thickness (mm), and plate width (mm) |
Our Marine Plate Rolling Machines come in various sophisticated types:
1. Symmetrical Up-Mode: The upper work roller performs vertical lifting movements, while the position of the two work rollers remains relatively unchanged.
2. Lower Roller Overall Horizontal Adjustment: The upper work roller moves vertically, and the lower work roller translates horizontally, ensuring precise adjustments.
3. Horizontal Lower Roller Adjustment: The upper work roller lifts vertically as the lower work roller translates horizontally, providing versatile operation.
4. Universal Roller: The upper work roller not only lifts vertically but also translates horizontally, with the positions of the two work rollers remaining relatively constant.
(The upper roller is adjustable both vertically and horizontally)
JSYZSK1 China-Origin CNC Machinery for Marine Plate Rolling Applications
Additionally, we offer a comprehensive Pipeline Rolling Production Line:
Overview
The process of a rolling machine seamlessly bending metal sheets involves continuous three-point bending. Based on the rolling temperature, it can be classified into cold rolling, hot rolling, and warm rolling. This high-precision machine excels at bending metal sheets of varying thicknesses into cylindrical, arc, rectangular, or other complex curved shapes. It is a cornerstone in industries such as metallurgy, construction materials, petroleum, chemicals, hydropower, bridges, defense, coal, mining, shipbuilding, boilers, aviation, and electrical transmission and transformation equipment manufacturing.
The upper roller functions as the primary driving roller on this advanced machine, featuring pre-bending and CNC rolling capabilities for the ends of metal sheets. It facilitates single-pass metal sheet feeding, completing both pre-bending and workpiece rolling without the need to turn around. The hydraulic motor on the upper roller features an instant brake, allowing precise halting of the rollers during bending and rolling. The lifting and lowering of the lower and side rollers are hydraulically controlled, with displacement managed by a computer. Displacement figures can be directly observed via CRT display using encoders for accurate detection. This machine offers unmatched simplicity, convenience, and high efficiency.
The machine boasts automatic leveling with screen display and synchronous accuracy of ±0.2mm. The tilting and resetting of the flipping bearing housing are hydraulically driven, and the tail of the upper roller includes a balancing mechanism for effortless removal of rolled workpieces and cylinders. It features a movable, independent operating platform for flexible operations. Equipped with safety interlock devices, this machine guarantees superior safety standards.
3PHASE AC
380V±20,50Hz±5Hz
Temperature: -10~45ºC
Accuracy:
≤±0.2mm
When synchronously controlling the position of the working rollers, the synchronization accuracy is ±0.2mm.
Structure and Performance
1. Tipping cylinder
2. Tipping head frame
3. Left frame
4. Upper roller
5. Side roller
6. Lower roller
7. Right frame
8. Balancing device
9. Upper roller driving device
10. Lower roller driving device (optional)
11. Side roller cylinder Lower roller cylinder
12. Roller cylinder
13. Base
14. Side support (Optional)
15. Top support system (Optional)
16. Feeding electric roller conveyor (Optional)
17. Hydraulic system
18. Electric control system
3.1Overview of the structure
The fundamental structural elements of the machine tool include the frame, upper roller, lower roller, side roller, flipping bearing housing, main drive, hydraulic, electrical, lubrication, and base sections.
The left and right frames of the machine are affixed to a unified base, forming the primary body of the machine. The left end of the upper roller's bearing housing is integrated into the flipping bearing housing, while the right end's bearing housing is installed within the right frame.
The upper roller stands as the principal driving component of the machine, seamlessly connected to the hydraulic motor via a planetary gearbox. In this setup, the upper roller remains stationary in position but engages in rotational motion, while the working roller undertakes both rotational and vertical movements, executing precise lifting and lowering actions.
The machine features strategically positioned oil cylinders for the lower and side rollers, installed within the guide grooves of the left and right frames. The cylinders' reciprocating motion enables the lower and side rollers to move vertically along the guide grooves and tilt, accommodating the rolling of conical workpieces and facilitating their correction and rounding. A flipping bearing housing on the left frame, actuated by the flipping oil cylinder, interacts with the head of the upper roller. The tail end of the upper roller includes a balancing device to stabilize and elevate the roller when the upper roller and tilting frame are open. The working roller's movement is precisely guided by high-quality linear slide rails.
The machine's operations are seamlessly managed from a centralized main operating console, ensuring intuitive, user-friendly control.
3.1.1 Work rollers
Being a fundamental element of a rolling machine, the work roller's quality and performance crucially influence the machine's durability and the accuracy of its rolling operations.
(1)Roller materials
The working rollers are crafted from high-strength rolling steel, passing through multiple rigorous processes like forging, tempering, quenching, stress relief, and precision lathe machining. These steps ensure the rollers possess high surface contact strength, preventing surface impressions during steel plate rolling. Consequently, they are capable of enduring long-term rolling operations while maintaining superior mechanical performance. Post rough processing, the rollers undergo tempering to achieve a hardness of HB240
~
300. Following precision processing, they are subjected to intermediate frequency quenching, attaining a hardness of HRC45-55. Adhering to the JB/ZG4289-86 standard for rolling steel, their stiffness aligns with (1/7001/1000) L, where L signifies the distance between the centerlines of the two side frames.
(2) The rotation of the work roller: the hydraulic motor connects to the planetary gearbox, transmitting torque directly to the work roller.
The four-roller rolling machine operates with the upper roller as the driving roller, powered independently by a hydraulic motor directly coupled to a high-power planetary gearbox (linear coupling), eliminating the need for intermediate gear transmission. This method stands as the pinnacle of energy efficiency. The hydraulic motor is fitted with an instant brake, ensuring precise halting of roller rotation during the pre-bending phase.
Schematic diagram of upper rollClamping pressure can be set:
To meet varied product rolling process requirements, the clamping force
between the upper and lower rollers can be pre-set to prevent
This approach effectively avoids overpressure indentations on soft materials.
The clamping force control is managed by the hydraulic station's relief valve.
3.1.2Bearings at both ends of the work rollers
Each end of all working rollers houses two roller bearings, which are made using Wafangdian shafts, recognized as esteemed products in China.
Each roller in the four-roller machine is meticulously engineered with high-performance self-aligning roller bearings that are industry best. These bearings expertly counteract the pressure from shaft misalignment during roller shaft rotation. The flexible movement of each shaft eliminates risks of scratches and cracks, while the internal design of the self-aligning bearings allows them to endure shaft misalignment and tilt. This foldable mobility prevents damage from reverse forces by accommodating fixed outer cover pressures.
The unparalleled advantage of these bearings is their ability to smoothly and safely move along the roller shaft's inclination, returning to their original position regardless of deviation. Conical rolling demands strict precision, necessitating the roller shaft's ability to tilt and endure unbalanced loads, which places immense pressure on the bearings. Self-aligning bearings redirect this load into an 'axial' mode, managing the folding impacts and ensuring smooth, safe self-rotation. By incorporating two self-aligning bearings on each roller shaft and leveraging 'permanent lubrication technology,' we eliminate the need for frequent bearing lubrication, ensuring durability throughout the product's lifespan.
3.2.1Racks and bases
The frame and seat of our coiler are crafted from premium domestic Q235A/Q345 steel. The components undergo CNC
machine cutting
, precise polishing, and welding. Post-welding, the structural parts are sent to a specialized heat treatment facility for stress relief annealing and CNC lathe machining. Each workpiece's records are meticulously maintained in our quality tracking system.
3.3.1Hydraulic system
Our hydraulic system is designed with an independent circuit, featuring dual main functions. One section powers the upper and lower working rollers, while the auxiliary section facilitates the lifting and lowering of the lower and side rollers and powers the tilting frame's flipping. Each circuit is supplied by a high-pressure oil pump driven by an electric motor, adopting a superimposed valve structure that offers:
Reducing device and installation space
No need for special installation skills, allowing quick and easy expansion or modification of the hydraulic system.
Avoiding the diverter valve synchronous system, which is prone to inconsistent pressure impacts between two cylinders,
Overcoming leakage, vibration, and noise issues in pipeline connections, thereby enhancing system reliability;
The stacked components design facilitates easy maintenance and inspection.
Each hydraulic circuit is equipped with two relief valves to regulate pressure. The maximum pressure for each circuit is set at 20MPa, primarily to control the main cylinder's pressure. Another valve is set at 16MPa, focusing on the tilting and balancing cylinders.
In each hydraulic circuit, the main cylinder utilizes two sets of stacked components to adjust movement speeds, accommodating various working speeds for side and lower rollers under different conditions.
High-precision displacement sensors on the left and right frames, along with the tilting frame, ensure synchronization accuracy of the main cylinders at both ends of each moving working roller. Through pressure sensors and a microcomputer control system, the pistons' displacement is monitored and adjusted, achieving the required synchronization accuracy at both ends.
a,
Employing unique pre-unloading pressure technology effectively avoids hydraulic shock, thereby extending the lifespan of pipelines and seals.
b,We select high-quality hydraulic components, specifically 'Yuyan' products, to ensure system stability.
c,The hydraulic system has corresponding detection points at all input and output ports, facilitating maintenance and fault inspection. The oil pump is of the bottom suction type with positive pressure. Additionally, filters, level gauges, all equipped with signaling devices, can automatically alarm for fault indication. Furthermore, the hydraulic station is independent of the machine base, making maintenance and upkeep convenient, while also being positioned away from heat sources.
d,The system is manufactured strictly in accordance with national and industry standards. The pipe bending radius is reasonable, not less than 90°, featuring smooth transitions and well-placed shock-absorbing pipe clamps. This effectively avoids impact and vibration, ensuring that the hydraulic pipeline remains free from shock and vibration.
e,The system design takes into full consideration high efficiency, energy conservation, reducing power wastage, and minimizing heat sources.
3.4.1Lubrication system
The machine's lubrication system, such as linear slide, work rollers and other lubrication, adopts centralised lubrication and manual lubrication in two ways. lubrication.
3.5.1Control system
The micro-control system includes hardware components such as the main electrical cabinet, control cabinet, and dedicated control software.
The system features two sets of operating systems: touchscreen control and manual control, allowing for convenient switching. Sensors are sourced from American or Italian brands to ensure positional accuracy and monitor the positions of each working roller.
Key technical specifications:
Average failure-free time: ≥20,000 hours
Display accuracy: ≤±0.2mm
Synchronization accuracy for lower roller lifting, side roller tilting, and displacement control: ≤±0.2mm
Sensor displacement resolution: ≤0.1mm
Core components and control principles of the micro-control system:
The four-roller rolling machine consists of an industrial control computer, a SIEMENS Programmable Logic Controller (PLC) with its digital and analog extension modules and peripheral circuits, displacement sensors, etc.
The industrial computer communicates with the Siemens PLC through a dedicated communication cable to obtain data such as lower roller displacement, displacement of front and rear side rollers (cylinders I and II), displacement of hydraulic cushions I and
II, balance cylinder, flipping cylinder, PLC input/output status, etc.
The computer and PLC, with the integration of the above information and intelligent processing, control the output of the PLC. Through intermediate relays, they control peripheral devices, motor operation, and hydraulic valve switching, ensuring the normal operation of the control system and maintaining system accuracy. Simultaneously, the computer control system displays various data, alarms, output states, etc., on the computer screen in a graphical and textual format.
Control system functions:
The PLC system can display various real-time data and rolling information.
The system is designed with advanced features, good operability, safe and reliable operation, excellent fault tolerance, and the following functions:
Fault self-diagnosis display and operation error intelligent identification
Real-time display of absolute positions at both ends of the rear side roller
Real-time display of absolute positions at both ends of the lower roller
Real-time display of tilting angles (degrees) for front and rear side rollers and both ends of the lower roller
Soft and hard limit protection for various moving parts
Power-off memory function: In case of sudden power outage during operation or machine shutdown after rolling, the PLC system automatically tracks and accurately displays the actual positions upon re-powering.
Safety Protection Function: In the event of unexpected situations, operators can swiftly and effortlessly shut down the equipment and system, ensuring the utmost safety of both the machinery and personnel.
Control Function:
The industrial computer seamlessly communicates with the Siemens PLC via a dedicated communication cable to acquire critical data such as the displacement of the front and rear side rollers, the PLC's input/output status, and more.
The computer and PLC, utilizing the aforementioned information and intelligent processing, control the PLC's output. Through intermediate relays, they manage peripheral devices, motor operations, and hydraulic valve switching, thereby ensuring the smooth and efficient operation of the control system.
3.6.1 Embedded Software for CNC 4 Roll Hydraulic Steel Plate Bending Machine Sheet Metal Bender Roller
The machine offers the convenience of invoking batch rolling data with just a single click. Our state-of-the-art control system software is equipped with an automatic rolling program, enabling one-click operations for data collection, calibration, storage, invocation, and post-calibration startup.
In automatic mode, the system can automatically feed the material and complete one-time circular forming. The software boasts features for data numbering, storage, and retrieval, capable of storing data for hundreds of specifications. This facilitates automated rolling for various sizes, with the flexibility to switch to manual operation programs as needed.
The software is designed to support the automatic rolling of circular workpieces and can also accommodate the automated rolling of non-circular shapes, such as square workpieces, enhancing its versatility.
Rolling Flow Chart
Main Configuration:
| Name of main parts |
Material |
| Upper roller device |
HB250~300
Tempering hardness HB250~300 |
| Lower roller device |
HB250~300
Tempering hardness HB250~300 |
| Side roller device |
HB250~300
Tempering hardness HB250~300 |
| Bed |
Welded structural parts |
| Right frame unit |
Welded structural parts |
| Tipping device |
Welded structural parts |
| Cylinder |
Finished product |
| Transmission system |
Hydraulic motor + planetary gear drive |
| Hydraulic system |
Yuji "Yuken" from Japan |
| Control system |
Siemens |
Our state-of-the-art CNC 4 Roll Hydraulic Steel Plate Bending Machine, also known as the Sheet Metal Bender Roller, is meticulously packed and loaded, ensuring it arrives at your location in pristine condition.
Our exceptional goods have a global footprint, showcasing our commitment to quality and international standards.
We warmly welcome our esteemed customers to visit our factory, where they can witness our advanced manufacturing processes and stringent quality controls firsthand.
Our Honors:
Nanjing Yunyan Digital Technology Co., Ltd is the prestigious exporting division of Jiangsu Yizhong CNC Machine Tool (Group) Co., Ltd.
Established in 2006, our esteemed group stands among China's elite machine tool manufacturers. Nestled in the Chengbei industrial area of Yangzhou city, Jiangsu province, our expansive facility spans 498,700 square meters and boasts nine advanced production lines. As a proud participant in the National Torch Plan, we are recognized as a leading High-tech enterprise.
Our diverse product portfolio features state-of-the-art CNC machining centers, CNC gantry drilling machines, CNC gantry drilling and milling machines, CNC boring and milling machine centers, plate planers and milling machines, oil press machines, CNC lathes, and leveling machines. Equipped with a formidable team of skilled technicians, we excel in providing bespoke OEM machinery solutions tailored to your needs.
Through relentless dedication over the years, we have fostered enduring partnerships with clients across the globe, including Russia, Australia, the United Kingdom, Italy, South America, Egypt, India, and beyond. We warmly invite your inquiries and look forward to establishing a fruitful collaboration.
Dedicated After Service:
Enjoy a 12-month warranty period, starting from the successful installation and trial operation date.
The equipment provided by the seller is brand new and unused. After installation, debugging, and operation, it meets or exceeds relevant national standards or the specific terms agreed upon by both parties.
The seller shall offer prompt technical support within 2 hours of receiving a call from the buyer. If the buyer is unable to resolve the issue independently, the seller will conduct troubleshooting within 24 hours in the seller's country. Any parts identified as having quality-related issues during the warranty period will be replaced at no extra cost.
Our professional technician team is available for installation and training at the customer's factory, with only a reasonable labor fee applied.
Application field
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