High Precision CNC Marine Plate Rolling Machine Tool
Application field
Introducing the W11NC Series Marine Plate Rolling Machine: your ultimate solution for precise and efficient rolling of circular plates, perfect for ship shells and groove-type bulkheads. Designed to adapt to your specific needs, this machine can be configured as either a symmetrical or asymmetrical three-roll coiling machine. It features a robust design with a rigid beam atop the upper roller and multiple sets of rollers between the beam and the lower roller. This strategic arrangement significantly enhances the stiffness of both the upper and lower rollers, ensuring optimal performance and durability. Experience the full power and drive of our three-roller system and elevate your marine fabrication capabilities to new heights.
| 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) |
The diverse types of Marine Plate Rolling Machines can be categorized as follows:
1. Symmetrical Up-Mode: The upper work roller performs vertical lifting movements while the positions of the two work rollers remain relatively unchanged.
2. Lower Roller Overall Horizontal Adjustment: The upper work roller moves vertically, while the lower work roller translates horizontally in an overall adjustment.
3. Horizontal Adjustment of Lower Rollers: The upper rollers are elevated vertically, while the lower rollers are moved horizontally.
4. Universal Roller: The upper work roller achieves both vertical lifting and horizontal translation, maintaining the relative positions of both work rollers.
(The upper roller is adjustable both vertically and horizontally)
CNC 4 Roll Hydraulic Steel Plate Bending Machine - Sheet Metal Bender Roller
We also offer the advanced Pipeline Rolling Production Line:
Overview
The Advanced CNC Marine Plate Rolling Machine Tool by JSYZSK1, originating from China, masterfully rolls metal sheets by bending them at three pivotal points, enabling cold, hot, and warm rolling processes. This versatile machine transforms metal sheets into cylindrical, arc, rectangular, and other curved shapes, making it indispensable in a vast array of industries such as metallurgy, construction, petroleum, chemicals, hydropower, bridges, defense, coal mining, shipbuilding, boilers, aviation, and electrical transmission equipment manufacturing.
Equipped with an upper roller serving as the primary driving force, our machine excels in both pre-bending and CNC rolling functions. It handles metal sheets efficiently-pre-bending ends and rolling workpieces without requiring any turnaround. The upper roller's hydraulic motor features an instant brake for precise stopping, while the hydraulic-driven lifting and lowering of the lower and side rollers ensure seamless operation. The displacement is controlled via computer, with encoders providing real-time data on a CRT display. Experience easy operation, unmatched convenience, and high efficiency with this state-of-the-art machine.
The machine boasts automatic leveling, a screen display with synchronous accuracy of ±0.2mm, and a hydraulically driven tilting and resetting flipping bearing housing. The upper roller's tail features a balancing mechanism for effortless removal of rolled workpieces and cylinders. A movable, independent operating platform offers flexibility, while safety interlock devices guarantee optimum 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 maintained at ±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 machine tool's fundamental structural components encompass the frame, upper roller, lower roller, side roller, flipping bearing housing, main drive, hydraulic, electrical, lubrication, and base sections.
The unified base securely mounts the machine's left and right frames, forming its main body. The upper roller's bearing housing is inserted into the flipping bearing housing on the left side, while the right side is installed within the right frame.
The upper roller acts as the primary driving roller, ingeniously linked to the hydraulic motor via a planetary gearbox. This seamless connection ensures the upper roller remains stationary, engaging solely in rotational motion. Meanwhile, the working roller not only rotates but also executes vertical movements, smoothly performing lifting and lowering actions with unparalleled precision.
The hydraulic oil cylinders, adeptly positioned within the guide grooves of the left and right frames, drive the lower and side rollers to glide effortlessly up and down, and tilt gracefully. This dynamic motion enables the rolling of conical workpieces and the precise correction and rounding of materials. A flipping bearing housing on the left frame, activated by the flipping oil cylinder, interacts with the upper roller, while the tail boasts a balancing device that elevates the roller when the tilting frame is open. High-quality linear slide rails ensure flawless guidance of the working roller's movement.
The machine's operations are masterfully centralized at the main operating console, offering streamlined control and enhanced user experience.
3.1.1Work Rollers
The work rollers are pivotal to the machine's performance, directly affecting its longevity and rolling precision.
(1)Roller Materials
Crafted from high-strength rolling steel, the working rollers undergo an array of rigorous processes, including forging, tempering, quenching, and precision lathe machining. These meticulous steps ensure their surface contact strength remains impeccable, preventing surface impressions during steel plate rolling. The rollers are designed to endure long-term use while maintaining optimal mechanical performance. After rough processing, they are tempered to a hardness of HB240, then precision processed and quench-hardened to HRC45-55, adhering to the JB/ZG4289-86 standard.
~
300. The stiffness conforms to (1/700-1/1000) L, where L is the distance between the centerlines of the side frames.
(2) The rotation of the work roller: the hydraulic motor is seamlessly connected to the planetary gearbox, transmitting torque directly to the work roller with exceptional efficiency.
In the four-roller rolling machine, the upper roller serves as the driving force, powered independently by a hydraulic motor linked to a high-power planetary gearbox. This direct linear coupling eliminates the need for intermediate gears, offering the most energy-efficient drive method. The hydraulic motor features an instant brake mechanism, ensuring precise cessation of roller rotation during pre-bending operations.
Schematic Diagram of Upper RollAdjustable Clamping Pressure:
To meet diverse rolling process requirements, the clamping force
between the upper and lower rollers can be precisely pre-set.
This prevents overpressure indentations on softer materials with remarkable efficiency.
The clamping force is expertly managed by the hydraulic station's relief valve.
3.1.2Bearings at Both Ends of the Work Rollers
Each end of all working rollers is equipped with two robust roller bearings, manufactured by Wafangdian shafts, a renowned brand in China known for its superior quality.
Each roller in the four-roller machine is outfitted with industry-recommended, highly durable self-aligning roller bearings. These bearings effectively counteract the pressure caused by shaft misalignment during roller shaft rotation. The flexibility and free movement of each shaft prevent scratches and cracks on the rollers. The internal design of these bearings allows them to endure roller shaft misalignment and tilt. This foldable mobility, when subjected to fixed outer cover forces, prevents reverse forces from damaging the roller shaft.
The advantages of these bearings are significant. Regardless of the roller shaft's deviation, it can move smoothly and safely along its inclination and return to its original position. Conical rolling demands much more stringent requirements because the roller shaft must tilt, leading to an unbalanced load on the shaft, placing enormous pressure on the bearings. Self-aligning bearings redirect this load into an axial mode, effectively controlling the impact of folding and allowing smooth, safe self-rotation. Our company employs two self-aligning bearings on each roller shaft, with 'permanent lubrication technology' ensuring no need for frequent bearing lubrication throughout the product's lifespan.
3.2.1Racks 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. Post-welding, the structural parts are sent to a professional heat treatment facility for stress relief annealing and CNC lathe machining. All workpieces are meticulously tracked in a quality tracking system.
3.3.1Hydraulic system
The machine system features an independent hydraulic circuit with two primary functions: the main drive section powers the upper and lower working rollers, while the auxiliary drive facilitates lifting and lowering of the lower and side working rollers, and powers the tilting frame flipping. Each hydraulic circuit is independently supplied by a high-pressure oil pump, driven by an electric motor. The system adopts a superimposed valve structure, characterized by:
Reducing device and installation space,
requiring no special installation skills, allowing for quick and easy expansion or modification of the hydraulic system,
avoiding the use of diverter valve synchronous systems, which are prone to inconsistent pressure impacts between two cylinders,
overcoming issues like leakage, vibration, and noise during pipeline connections, thus enhancing the hydraulic system's reliability,
and providing convenient maintenance and inspection due to the use of stacked components.
Each hydraulic circuit is regulated by two relief valves. The maximum set pressure for each circuit is 20MPa, primarily controlling the main cylinder pressure. Another relief valve is set at 16MPa, mainly controlling the tilting and balancing cylinder pressures.
In each hydraulic circuit, the main cylinder comprises 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 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 to meet 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 features dedicated detection points at all input and output ports, significantly simplifying maintenance and fault diagnosis. The bottom-suction oil pump operates with positive pressure and is complemented by filters and level gauges equipped with signaling devices that automatically trigger fault alarms. Additionally, the independent hydraulic station, detached from the machine base and distanced from heat sources, enhances maintenance convenience.
d. Manufactured in strict compliance with national and industry standards, the system ensures a pipe bending radius of no less than 90°, featuring smooth transitions and strategically placed shock-absorbing pipe clamps. This meticulous design effectively prevents impact and vibration, maintaining the hydraulic pipeline's integrity.
e. The system design meticulously prioritizes high efficiency and energy conservation, significantly reducing power wastage and minimizing heat generation.
3.4.1Lubrication system
The machine's lubrication system, essential for components such as linear slides and work rollers, employs centralized and manual lubrication methods to ensure optimal performance and longevity.
3.5.1Control system
The micro-control system comprises key hardware components, including the main electrical cabinet, control cabinet, and specialized control software.
The system offers dual operational modes: touchscreen control and manual control, providing flexible operational switching. High-precision sensors from American or Italian brands ensure accurate positional monitoring 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 integrates an industrial control computer with a SIEMENS PLC, including digital and analog extension modules, peripheral circuits, and displacement sensors.
The industrial computer communicates with the Siemens PLC via a dedicated communication cable to gather data such as lower roller displacement, displacement of front and rear side rollers (cylinders I and II), displacement of hydraulic cushions, balance cylinder, flipping cylinder, and PLC input/output status.
II, balance cylinder, flipping cylinder, PLC input/output status, etc.
With integrated data and intelligent processing, the computer and PLC control the PLC's output. Through intermediate relays, they manage peripheral devices, motor operations, and hydraulic valve switching, ensuring system accuracy and reliable control. Simultaneously, the computer system graphically displays various data, alarms, and output states on the screen.
Control system functions:
The PLC system provides real-time display of various data and rolling information.
The system is designed with advanced features, ensuring excellent operability, safe and reliable operation, and superior fault tolerance, including the following functions:
Fault self-diagnosis display and intelligent operation error 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 lower roller ends
Soft and hard limit protection for various moving parts
Power-off memory function: In events of sudden power outage or machine shutdown after rolling, the PLC system auto-tracks and accurately displays actual positions upon reactivation.
Safety Protection Function: In the event of unexpected situations, operators can effortlessly and swiftly shut down the equipment and system, thereby ensuring the utmost safety for both the machinery and the personnel involved.
Control Function:
The sophisticated industrial computer interfaces with the Siemens PLC via a dedicated communication cable, acquiring essential data such as the displacement of the front and rear side rollers and the PLC input/output status.
Through the seamless integration of acquired data and intelligent processing, the computer and PLC collaboratively manage the PLC's output. Utilizing intermediate relays, they deftly control peripheral devices, motor operations, and hydraulic valve switching, 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 a single click. Our control system software is equipped with an advanced automatic rolling program, enabling one-click operations for data collection, calibration, storage, invocation, and startup post-calibration.
In automatic mode, the machine can autonomously feed the material and accomplish one-time circular forming. The software boasts features for data numbering, storage, and retrieval, capable of retaining data for hundreds of specifications, thus streamlining automated rolling for diverse sizes. The system is also adaptable to manual operation programs and can seamlessly switch to manual mode when required.
The software not only excels at automatic rolling of circular workpieces but is also engineered to support the automated rolling of non-circular shapes such as square workpieces.
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 carefully loaded to ensure it reaches you in pristine condition.
Our exceptional goods are cherished by customers around the globe, earning us a stellar international reputation.
We warmly welcome customers from all corners of the world to visit our factory and witness firsthand the meticulous craftsmanship behind our products.
Our Honors:
Nanjing Yunyan Digital Technology Co., Ltd serves as the distinguished exporting division of Jiangsu Yizhong CNC Machine Tool (Group) Co., Ltd.
Established in 2006, our group is heralded as one of the premier machine tool manufacturers in China. Located in the Chengbei industrial area of Yangzhou city, Jiangsu province, we proudly span 498,700 square meters and operate nine state-of-the-art production lines. Recognized as a National Torch Plan and High-tech enterprise, our commitment to excellence is unwavering.
Our extensive product range encompasses CNC machining centers, CNC gantry drilling machines, CNC gantry drilling and milling machines, CNC boring and milling centers, plate planers and milling machines, oil press machines, CNC lathes, and leveling machines. Furthermore, with the adept skills of our robust technician team, we excel in crafting custom OEM machines tailored to meet specific needs.
Through relentless dedication over the years, we have forged enduring and close-knit relationships with esteemed clients from Russia, Australia, the United Kingdom, Italy, South America, Egypt, India, and numerous other regions. We warmly invite you to consult with us.
Comprehensive After Service:
Enjoy a 12-month warranty period, commencing from the successful installation and trial operation date.
Our equipment, provided by the seller, is guaranteed to be brand new and unused. Post-installation, debugging, and operation, its performance will align with the pertinent national standards or the agreement established between the parties.
Upon receiving a service call from the buyer, the seller will offer expert technical support within 2 hours. Should the buyer be unable to independently resolve the issue, the seller will undertake troubleshooting within 24 hours within the seller's country. Any parts identified as having quality-related issues during the warranty period will be replaced at no cost.
Our professional technician team is at your service, offering installation and training at your factory for a reasonable labor fee. Benefit from our expertise to ensure optimal operation.
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