W12-40×2500 CNC Hydraulic Four roller Plate Rolling Machine
We also have pipeline rolling machine production line :
Product Description
Overview
The process of a rolling machine rolling metal sheets involves the continuous bending of the sheets at three points. Depending on the rolling temperature, it can be classified into cold rolling, hot rolling, and warm rolling. This machine is primarily used to bend metal sheets of a certain thickness into cylindrical, arc, rectangular, or other curved shapes. It is an essential piece of equipment in industries such as metallurgy, construction materials, petroleum, chemicals, hydropower, bridges, war, coal, mining, shipbuilding, boilers, aviation, and the manufacturing of electrical transmission and transformation equipment.
The upper roller serves as the main driving roller on this machine, which features pre-bending and CNC rolling functions for the end portions of the metal sheets. It can feed the metal sheets once, completing both pre-bending at the sheet ends and the rolling of the workpiece without the need to turn around. The hydraulic motor on the upper roller is equipped with an instant brake, allowing the rollers to accurately stop rotating during the bending and rolling process. The lifting and lowering of the lower roller and side rollers are all hydraulically driven, with displacement controlled by the computer. The displacement of the lower roller and side rollers can be directly observed through CRT display by using encoders for detection. The machine offers advantages such as simple operation, convenience, and high efficiency.
The machine can automatically level, 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 is equipped with a balancing mechanism for easy removal of the rolled workpiece and cylinder. It includes a movable independent operating platform for flexible movement. The machine is equipped with safety interlock devices, ensuring good safety.
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.
Product Parameters
Main technical parameters of the CNC Hydraulic Four roller Plate Rolling Machine
| |
Item |
Unit |
Parameter |
| No. |
Equipment Name |
|
CNC Hydraulic Four-roller Plate Rolling Machine |
| Specification |
|
W12-40×2500 |
| 1 |
Maximum thickness of rolled plate |
mm |
T40*B2500*φ1200(σs≤245MPa) |
| 2 |
Maximum pre-bending plate thickness |
mm |
T30*B2500*φ1200(σs≤245MPa) |
| 5 |
Maximum width of rolled plate |
mm |
2500 |
| 6 |
Working length of roll |
mm |
2550 |
| 7 |
Remaining straight edge length |
mm |
≤2 times board thickness |
| 8 |
Yield limit of rolled sheet |
MPa |
245 |
| 9 |
Coiling speed |
m/min |
3.5 |
| 10 |
Upper roll diameter |
mm |
Φ520 |
| 11 |
Lower roll diameter |
mm |
Φ480 |
| 12 |
Side roll diameter |
mm |
Φ420 |
| 13 |
Stick moving mode |
/ |
hydraulically driven |
| 14 |
Hydraulic system pressure |
MPa |
22 |
| 15 |
Maximum working pressure of hydraulic system |
MPa |
20 |
| 16 |
Roller driving mode |
/ |
Hydraulic motor + planetary gearbox |
| 17 |
Main hydraulic motor power |
Kw |
37 |
Control method (CNC) |
Compatible with CNC automatic and manual control |
| Our company's control system features an automatic rolling program, enabling one-touch operation. It automatically feeds the material, completes one-time circular and arc rolling forming. Additionally, it comes with data numbering, storage, and retrieval functions, capable of storing hundreds of sets of data. This facilitates automated rolling for various specifications. The system is compatible with manual operation programs, allowing manual operation when necessary. |
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
3.1 Overview of the structure
The basic structural components of the machine tool include the frame section, upper roller section, lower roller section, side roller section, flipping bearing housing section, main drive section, hydraulic section, electrical section, lubrication section, and base section.
The left and right frames of the machine are mounted on a unified base, forming the main body of the machine. The left end of the upper roller's bearing housing is inserted into the flipping bearing housing, while the right end's bearing housing is installed within the right frame.
The upper roller serves as the main driving roller on the machine, directly connected to the hydraulic motor through a planetary gearbox. In this configuration, the upper roller remains in a fixed position and only undergoes rotational motion, while the working roller engages in both rotational and vertical movement, performing lifting and lowering motions.
The oil cylinders for the lower roller and side roller on the machine are respectively installed in the guide grooves of the left and right frames. The reciprocating motion of the cylinders allows the lower roller and side roller to move up and down along the guide grooves and also tilt, facilitating the rolling of conical workpieces and the correction and rounding of the workpieces. There is a flipping bearing housing on the left frame, which can be opened and closed by the flipping oil cylinder, driven to achieve interaction with the head of the upper roller. The tail of the upper roller has a balancing device, which balances and lifts the upper roller when the upper roller and the tilting frame are open. The motion of the working roller is guided by high-quality linear slide rails.
The control of the machine is centralized on the main operating console.
3.1.1 Work rollers
One of the most crucial components of a rolling machine, its quality and performance directly impact the machine's lifespan and rolling accuracy.
(1) Roller materials
The working rollers are made of high-strength rolling steel, undergoing multiple processes such as forging, tempering, quenching, tempering, stress relief, and precision lathe machining (Note: The processing procedures for the rollers may vary based on user requirements). The goal is to ensure a high surface contact strength of the working rollers, preventing surface impressions during the rolling of steel plates. This ensures that the rollers can meet the requirements of long-term rolling of steel plates and guarantee their comprehensive mechanical performance. After rough processing, they undergo tempering treatment with a hardness of HB240~300, and after precision processing, they undergo intermediate frequency quenching with a hardness of HRC45-55. In accordance with the JB/ZG4289-86 standard for rolling steel, the stiffness complies with (1/7001/1000) L, where L refers to the distance between the centerlines of the two side frames.
(2) The rotation of the work roller: the hydraulic motor is connected to the planetary gearbox, and then the torque is transmitted to the work roller.
The four-roller rolling machine is driven by the upper roller (as shown in the diagram below): the upper roller serves as the driving roller, independently powered by a hydraulic motor directly coupled to a high-power planetary gearbox (linear coupling), without intermediate gear transmission. This is the most energy-efficient driving method. The hydraulic motor is equipped with an instant brake, ensuring accurate cessation of roller rotation in the pre-bending state.
Schematic diagram of upper roll
Clamping pressure can be set:
For different product rolling process requirements, the clamping force
between the upper and lower rollers can be pre-set to effectively prevent
This effectively prevents overpressure indentation on soft materials.
The clamping force is controlled by the relief valve of the hydraulic station.
3.1.2 Bearings at both ends of the work rollers
There are two roller bearings at each end of all working rollers, and the roller bearings are made of Wafangdian shafts, which are famous brand products in China. bearings.
Each roller in the four-roller machine is equipped with highly durable self-aligning roller bearings recommended by the industry. This effectively counteracts the pressure caused by shaft misalignment during roller shaft rotation. The ability of each shaft to move freely and flexibly avoids the risk of scratches and cracks on the rollers. The internal design of these self-aligning bearings allows them to withstand roller shaft misalignment and tilt. When subjected to fixed outer cover forces, this foldable mobility prevents damage to the roller shaft from reverse forces.
The advantages of these bearings are that, regardless of the position to which the roller shaft deviates, it can smoothly and safely move along the inclination of the roller shaft, ultimately returning to its original position. The requirements for conical rolling are much more stringent because it necessitates that the roller shaft be able to tilt, posing an unbalanced load on the roller shaft. This places significant pressure on the bearings. By using self-aligning bearings, this load can be directed into an "axial" mode, effectively controlling the impact of folding and allowing for smooth, safe self-rotation. Our company employs two self-aligning bearings on each roller shaft, utilizing "permanent lubrication technology" throughout the entire lifespan of the product, eliminating the need for frequent bearing lubrication.
3.2.1 Racks and bases
The frame and seat of the coiler produced in the factory are made of domestic Q235A/Q345 high-quality steel, which is CNC machine cut , polished and welded, and then the welded structural parts are sent to the professional heat treatment factory for stress relief annealing and CNC lathe machining. All records of the workpieces are included in the quality tracking system.
3.3.1 Hydraulic system
The machine system is designed with an independent hydraulic circuit, consisting of two main functions. One part serves as the main drive section, providing power to the upper and lower working rollers. The other part acts as an auxiliary drive, facilitating the lifting and lowering of the lower and side working rollers, as well as providing power for the flipping of the tilting frame. Each hydraulic circuit is independently supplied by a high-pressure oil pump driven by an electric motor. The system adopts a superimposed valve structure. Its characteristics are:
Reducing device and installation space
No special installation skills are required, and it can be quickly and easily expanded or modified for the hydraulic system.
Avoiding the use of a diverter valve synchronous system, which is susceptible to the impact of inconsistent pressure between two cylinders,
Overcoming leakage, vibration, and noise issues during pipeline connections, thereby increasing the reliability of the hydraulic system;
Due to the use of stacked components, it is convenient for maintenance and inspection.
Each hydraulic circuit is controlled by two relief valves to regulate pressure. The maximum set pressure for each circuit is 20MPa, primarily controlling the pressure of the main cylinder. Another relief valve is set at 16MPa, mainly controlling the pressure of the tilting cylinder and the balancing cylinder.
In each hydraulic circuit, the main cylinder consists of two sets of stacked components to adjust the movement speed of the main cylinder, meeting different working speeds for the side and lower rollers under various conditions.
To ensure the synchronization accuracy of the main cylinders at both ends of each moving working roller, high-precision displacement sensors are installed on the left and right frames as well as the tilting frame. Through pressure sensors and a microcomputer control system, the displacement of the main cylinder pistons is monitored and adjusted, meeting the synchronization accuracy requirements at both ends of the working roller.
a,The unique pre-unloading pressure technology is employed to effectively avoid hydraulic shock, thereby enhancing the lifespan of pipelines and seals.
b,Hydraulic components are selected from high-quality products, specifically "Yuyan" products, ensuring the stability of the hydraulic system.
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.
3.4.1 Lubrication 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.
3.5.1 Control 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 case of unexpected situations, operators can easily and promptly shut down the equipment and system to ensure the safety of both equipment and personnel.
Control function:
The industrial computer communicates with the Siemens PLC through a dedicated communication cable to obtain data such as the displacement of the front and rear side rollers, 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, achieving the goal of normal operation of the control system.
3.6.1Embedded software for CNC four-roll single-forming plate rolling machine
The machine can conveniently invoke batch rolling data with a single click. Our company's control system software is equipped with an automatic rolling program that allows for one-click operations such as data collection, calibration, storage, invocation, and startup after calibration.
In automatic mode, it can automatically feed the material and complete one-time circular forming. The software includes features for data numbering, storage, and retrieval, capable of storing data for hundreds of specifications, facilitating automated rolling for various sizes. The system is compatible with manual operation programs and can be switched to manual operation when needed.
The software not only supports the automatic rolling of circular workpieces but also accommodates the automated rolling of non-circular shapes such as square workpieces.
Rolling flow chart
Packaging & Shipping
CNC Hydraulic Four roller Plate Rolling Machine packing and loading
Goods sells all over the world :
Customers visit our factory :
Our Honors:
Company Profile
Nanjing Yunyan Digital Technology Co. Ltd is the exporting department of Jiangsu Yizhong CNC Machine Tool (Group) Co., Ltd .
Our group is one of the Top machine tool factories in China, which set up in 2006, located in Chengbei industrial area, Yangzhou city, Jiangsu province. It covers an area of 498700 square meters and nine production lines. We're also the National Torch Plan and High-tech enterprise.
Our main products includes CNC machine center ,CNC gantry drilling machine ,CNC gantry drilling and milling machine ,CNC boring and milling machine center ,Plate Planer and milling machine ,oil press machine,CNC lathe and leveling machine. Meanwhile , with a powerful technician team, OEM machine is our strong suit .
With many years' hard-working, we have built long term and close cooperation relationships with many friends, such as Russia, Australia, United Kingdom, Italy, South Americas, Egypt, India and so on,welcome your consulting .
After Sales Service
After service :
The warranty period is 12 months, calculated from the date of successful installation and trial operation.
The equipment provided by the seller is new and unused. The performance of the equipment, after installation, debugging, and operation complies with the relevant national standards or stipulated in the agreement between the parties.
The seller shall provide relevant technical support within 2 hours upon receiving a phone call from the buyer. In the event that the buyer is unable to resolve the issue independently, the seller will conduct troubleshooting at the within 24 hours in sellers' country . Parts identified as quality-related issues during the warranty period will be replaced free of charge.
We have professional technician team and we could offer installation and training in customers' factory , just charge for reasonable labor fee .
FAQ
What equipment can you get from our factory ?
Lathe machine
CNC Vertical machine center
Leveling machine
Plate edge milling machine
Boring milling machine
Edge planer
Gantry drilling and milling machine
Oil pressure
Rolling machine
We support customized machines , welcome your asking .
Why choose Jiangsu Yizhong Machine Tool Co.,Ltd?
Quality guarantee :
We have our own factory 498700m2 and we have mature manufacturing experiences since 2006 .
Before machine sending , we will be debugging a long time and confirm it could run well .
We have a rigorous QA and QC procedures and confirm each process following the orders' standard strictly . welcome our customer-self coming to check the machine tools quality .
Delivery time :
Usually our delivery time from 10 working days to 6 months . according to the machines you want to buy .some machines have machine bed in stock .
When we quote you , we will write the machine tool delivery time , and we will abide it carefully .
Advanced technician team :
We recognize that technical innovation is very important for a manufacturer , so our factory set up the Jiangsu Yizhong Industrial design and reach institute years ago ,which makes our factory powerful in customized machines .
If some technical questions our sales person can not answer , they will ask them and they can give a quick response .
By the way , our engineers are available to customers' local factories to assist them to do installation , operation guide and machine tool upkeep .
Sales team :
Our salesmen all are trained before they serve to our customers in factory , so most questions about the machine tools , they can give fast response ,which will save our customers' time .
Our salesmen all love their jobs , so they have passions when working . if you have any technical questions could ask them better before 12pm ,China time .
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