1. The structure of the equipment
The machine belongs to the hydraulic three-roller plate bending machine, which is used to roll the steel plate into a cylindrical, circular arc and rounding function; The upper roller can be moved vertically; The pre-bending is achieved by the horizontal movement of the lower roller, and the lower roller is in an asymmetrical position relative to the upper roller; When rounding and calibrating, the working roller is driven to provide the coiling torque for the coiled sheet; The elevation of the lower roller remains unchanged, which is convenient for feeding and operation;
2.Main technical parameters
| No |
Name |
Unit |
Parameters |
| 1 |
Three roll plate bending machine type |
/ |
Variable center distance lower roller level adjustable |
| 2 |
Rolled sheets yield to the limit |
MPa |
≤245 |
| 3 |
Maximum coil thickness |
mm |
150 |
| 4 |
Maximum pre-bent plate thickness |
mm |
45 |
| 5 |
Minimum roll diameter at full load |
mm |
F20 00 |
| 6 |
Maximum bin width |
mm |
3200 |
| 7 |
Remaining straight edge thickness |
mm |
≤ 2.5 times the thickness of the plate |
| 8 |
Roll speed |
m/min |
4 |
| 9 |
Upper roll diameter |
mm |
F460 |
| 10 |
Lower roll diameter |
mm |
Φ400 |
| 11 |
Two lower roller center distances |
mm |
480-680 |
| 12 |
Work roller material |
/ |
42CrMo (tempered HB260-300). |
| 13 |
The way the working roller moves |
/ |
Hydraulic cylinder driven |
| 14 |
Hydraulic system pressure |
MPa |
20 |
| 15 |
Hydraulic motor torque |
KN.m |
12 |
| 16 |
Total installed power |
KW |
50 |
| 17 |
Hydraulic cooling system |
/ |
Oil cooler |
| 18 |
Roller drive method |
/ |
Hydraulic motor + planetary gear reducer |
| 19 |
Lubrication system |
/ |
It adopts automatic lubrication at start-up and timed forced lubrication |
20 |
operating system |
/ |
Two sets of operation systems: remote control and movable operating platform
system, but mutually secure interlocking, only one system can be used at a time. Touchscreen movable operator station. |
| 21 |
Control mode |
/ |
Manual (wireless) + electronically controlled |
| No |
Name |
| 1) |
Front frame |
| 2) |
Rear frame |
| 3) |
chassis |
| 4) |
Roll on |
| 5) |
Coupling |
| 6) |
Planetary reduction gears |
| 7) |
Hydraulic motor |
| 8) |
Lower roller |
| 9) |
The upper roller moves the drag plate |
| 10) |
The lower roller moves the cylinder |
| 11) |
Front opening unit |
| 12) |
Reverse and support systems |
| 13) |
Hydraulics and systems |
| 14) |
Power supply unit |
| 15) |
Control cabinet |
| 16) |
Protection and security equipment |
The main structural components of the bending machine are as follows:
1) Mechanical structure
2) Upper roller device
3) Lower roller device
4) Overturning device
5) Option attachments
6) Hydraulic system
7) Lubrication system
8) Electrical system
9) Safety device
3-1. Upper roller device
1) Upper roller 2) Hydraulic motor 3) Reduction gear 4) Overturn bearing seat 5) Fixed bearing housing 6) Main oil Cylinder 7) Skateboard
(Illustration of upper roller device).
The upper roller device is mainly composed of upper roller, main oil cylinder, upper roller bearing seat, double row spherical rolling bearing, etc.
The material of the upper working roller is 42CrMo, which has high strength and toughness, and is heat treated HB260~300.
The upper roller is preset with a drum shape with 50% uniform load, which improves the rigidity of the upper roller and greatly improves the straightness of the product.
Two master cylinders provide the pressing force required to coil the plate, the cylinder block is 45 and the piston is 45 steel forgings, the tempering treatment is HB215-255, and the main cylinder is Yx seal.
Double row spherical bearings are selected for low-speed, heavy-duty bearings.
The lifting and lowering synchronization of the upper roller is controlled by PLC, and the synchronization accuracy is ±0 Within 20mm.
Both ends of the upper roller can be raised and lowered independently in order to realize the coiling of the cone.
The main transmission device is composed of hydraulic motor + planetary reducer, which directly drives the upper roller.
The main drive can be reversed forward and reverse to power the coiling of the plates.
A hydraulic motor that converts pressurized fluid energy into mechanical energy and then to the shaft via planetary reduction gears.
1)Hydraulic motor 2) cycloid reduction gear 3) coupling 4) stop gear
3-2. Lower roller and horizontal moving device
1) Lower roller 2) side hydraulic cylinder 3) bearing housing 4) slide plate 5) guide rail 7) horizontal guide 8)Anti-collision travel limit block 9)Position sensor
(Illustration of lower roller device).
The lower roller device is composed of lower roller, lower roller bearing seat, double row spherical rolling bearing, etc.
The material of the lower working roller is 42CrMo, which has high strength and toughness, and is heat treated HB260~290.
Double row spherical bearings are selected for low-speed, heavy-duty bearings.
The horizontal movement of the lower roller is driven by the cylinder respectively, the structure is external, and it is installed on the inside of the frame bed; The overall horizontal movement synchronization of the lower roller is controlled by the PLC, and the synchronization accuracy is ±0 Within 2mm.
3-3. Frame, support beam and chassis part
The mechanical structure of the machine is mainly composed of 3) bed, 4) front frame 1) rear frame 2)The body consists of a base
The fixed side frame and the overturned side frame are composed of steel plate welded structure, which has the advantages of light weight, low cost, good workmanship and short production cycle.
The racks on both sides are fixed with flat keys, fixed on the base by bolts, and the connecting beams are used to connect the racks on both sides together, so that the whole machine has good rigidity.
The racks on both sides are equipped with lower roller motion guides, which are a closed frame structure. The force in the process of bending is borne by the racks on both sides, and the base not only plays the role of supporting the weight of the machine and ensuring the accuracy of the equipment, but also connects the whole machine into one. Designed for heavy-duty welded box beams with sufficient strength and stiffness to withstand maximum downforce at maximum loads.
The mounting surfaces on the edges of the rack and other parts are machined.
The sliding rails are lined with wear-resistant materials and have a rail gap adjustment device. Each rail may be exposed with a protective cover to prevent damage to the rail.
3-4. Balancing device and tipping device
1) Support support 2) Stroke limit switch
(Balancing device)
1) Upper roller 2) Vertical front cylinder 3) Open the tie at the front end
4) Overturn the cylinder 5) Overturn the bearing seat
(tipping over device).
The balancing device is composed of a support bracket and a limit switch.
After the bearing body of the upper roller is overturned, the balancing device presses the tail of the upper roller to maintain the balance of the upper roller.
The tipping device is composed of an overturned cylinder, etc., after the product is completed, open the tip-over bearing seat and take out the product.
3-5. Lubrication system
Reasonable lubrication of the transmission parts and sliding surfaces of the machine is an effective measure to reduce power consumption and improve the life of the machine, so it is necessary to select a reasonable lubricating grease and establish the necessary lubrication system.
3-5-1. Lubrication method
According to the working conditions of this machine, three ways are adopted: box lubrication, automatic centralized lubrication and regular oil lubrication.
The neck position of the upper roller and the lower roller shaft adopts spherical roller bearings, and the grease is applied fully during assembly and large and medium repairs, and manual regular lubrication is used when working at ordinary times. The upper and lower side roller bearings should be disassembled after one year or 2000 hours of work in the machine, and the bearings should be cleaned and replaced with new grease. Each sliding guide surface adopts an automatic centralized lubrication system. The gear reducer of the main drive of the upper and lower rollers adopts oil pool splash lubrication.
3-5-2, the choice of lubricating oil
For the aligning roller bearings of each roller, it is recommended to use general lithium-based grease No. 1 (GB7324-1994), if other types are used when the grease is substituted, the dropping point must not be less than 1600C, and the penetration degree is 325~360 range of grease.
Automatic centralized lubrication recommends the use of No. 00 extreme pressure lithium base grease (GB7323-1994) reducer to choose 220# industrial gear oil.
3-5-3,Lubrication system and precautions
(1) Before each shift of work, oil should be filled into each lubrication point to check whether the lubricating oil in the gearbox is at the specified oil level.
(2) The lubricating oil must be clean, meet the standard, and must not let impurities mix.
(3) Each sliding mating surface should be kept clean, and the oxide scale and dust generated during the production process should be removed in time to prevent early wear of parts.
(4) The automatic centralized lubrication point is generally supplied with oil every 8 hours, and the time is about 30 minutes; The upper, lower and side roller journals are manually lubricated regularly, and sufficient grease is applied during assembly and large and medium repairs, and the oil is supplied once every three months. The specific lubrication system depends on the load operation.
(5) The lubricating oil of the deceleration chassis body is replaced every half, at least once a year; If the machine is in continuous working condition for a long time, it is replaced every three months, at least once every six months.
(6) The whole lubrication system should be cleaned once 150 hours after the machine starts working, and at least once a year later. If the machine is in a continuous full load state for a long time, it should be cleaned once every six months.
4. Hydraulic system
4.1. General overview
The function of the hydraulic system: drive the rotation of the upper and lower rollers, drive the lower roller to do horizontal movement by the oil cylinder, the pouring and reset movement of the inverted head body and the balance of the upper roller.
It can accurately control the vertical lifting of the upper roller and the horizontal displacement of the lower roll. The work roller can be kept in any position.
The machine is equipped with a hydraulic circuit that controls the synchronous rotation of the rollers to maintain consistent line speed, so that the workpiece can be straightened and positioned quickly and accurately before winding.
The integrated valve block design of the hydraulic control system for easy maintenance ensures good functionality and operational reliability of the equipment, with oil filtration, industrial chiller cooling system. All hydraulic systems must not leak oil.
The system pipeline is neatly arranged and easy to operate; The bending of metal oil pipes in hydraulic pipelines is natural and reasonable.
The hydraulic oil tank is equipped with an industrial cooler to reduce and stabilize the oil temperature, which cannot be greater than 55 °C.
The hydraulic components adopt first-class famous brand products to ensure that the hydraulic system can be used for a long time without leakage.
For convenient commissioning and maintenance, there are suitable pressure measuring points and bleed heads on the hydraulic devices and pipelines.
The hydraulic station, hydraulic components and pipelines are permanently marked in detail, and consistent with the drawings, providing detailed common fault phenomena of the hydraulic system of the bending machine and their elimination methods.
The hydraulic system has oil suction and return oil filters to ensure the cleanliness of the system, and air filters to ensure the evaporation of water in the oil tank.
The hydraulic system is composed of oil pump, valve group, fluid connection, hydraulic accessories, etc.
The hydraulic valve adopts the superimposed valve series, and the pipeline layout is simple and the maintenance and debugging are convenient.
The system consists of four circuits, overpressure protection and pressure regulation circuit, synchronous circuit, speed loop, and working roller speed control circuit.
The pressure regulation circuit regulates the system working pressure through the main relief valve. The system working pressure is 20MPa.
The synchronous circuit is synchronized by the proportional valve to the horizontal movement of the lower roller; The displacement sensor detects that the positioning accuracy of the upper roller synchronization ± 0 2mm.
The speed loop controls the overturning and reset of the machine on the tipping side, and adjusts the throttle speed of the return circuit through the throttle valve.
Servo technology is applied to control the flow rate and control the speed of the working roller by controlling the proportional valve.
4-2. Various protections
The hydraulic system has a monitoring function, the hydraulic system each key pressure output point and oil temperature to monitor, when the fault occurs, the system can automatically stop the alarm, and prompt the fault point.
The horizontal movement of the lower roller and the tipping of the tipping frame are respectively protected by relief valves.
5. Electrical control system
5-1. General overview
The equipment electronic control system consists of an electric control cabinet, an operation console and a wireless remote control. Power supply three-phase four-wire system 380V/50Hz (voltage fluctuation ± 10%).
The control circuit adopts PLC programmable controller system, which has few relays, reliable action and long life.
The control cabinet is equipped with all control buttons and indicator lights for the completion of the product rolling process to control the operation of the whole machine.
5-2. Various protections
Each motor has a corresponding circuit breaker for overcurrent short-circuit protection and thermal relay for overload protection;
The horizontal movement of the lower roller has a corresponding limit switch for limit protection;
The tipping and resetting of the tipping cylinder are respectively equipped with upper and lower limit switch limit protection;
5-3. Various interlocks
After the tipping frame is fully reset, the upper roller lifting, the horizontal movement of the lower roller and other actions can be carried out ("tipping frame reset" is detected by the limit switch);
When the upper roller is located in the upper position, the lower roller moves horizontally and the overturned side falls separately cannot be carried out (the "upper roller upper position" limit switch is used for detection);
5-4. Fault indication
When the motor is overloaded, the fault indicator prompts;
When the PLC fails, the fault indicator light prompts.
6. CNC system
6-1. General overview
The whole machine has numerical control and manual control system, which can be easily converted. It has the characteristics of strong anti-interference, long service life, seismic resistance and stable operation. The control system has screen display function, program control function, soft protection function, and man-machine dialogue function. The operating control cabinet (box) should be two, one of which can be moved around the device.
6-2. The function of numerical control
Real-time monitoring capabilities
The computer screen displays the displacement amount of the upper roller main cylinder, the horizontal movement of the lower roller, the upper roller pressure and lower force, and intuitively displays the real-time status of each movement, the relative position and the output status of the hydraulic solenoid valve when the upper roller rises and falls, the lower roller moves horizontally, and the overturning frame action.
Human-machine dialogue function
Through the touch screen input and display, the input, editing, modification, storage and other functions of the rolled workpiece parameters can be realized;
The computer automatically detects and controls the position of both ends of the upper and lower rollers according to the set parameters to ensure that the synchronization accuracy is ± 0 2mm.
The displacement sensor has a displacement resolution of 0.05mm and a display accuracy of ±0.05mm.
It has automatic fault diagnosis function.
It has the function of soft limit protection of each component.
7. Technical characteristics of plate bending machine
7-1. Working roller drive
The main drive system of the bending machine adopts a hydraulic motor plus a planetary reducer to directly drive the upper working roller to rotate and provide the torque required by the bending machine, and can adjust the speed according to the requirements of the bending process. Compared with the traditional transmission method, it not only greatly reduces the floor space, but also avoids the inconvenience of the traditional transmission method in installation and adjustment, which is convenient for the installation and transportation of the machine when changing the site, and also avoids the transmission unevenness caused by the inconsistency between the main engine and the transmission part when making the foundation.
7-2. Horizontal movement device
a. The horizontal movement mechanism of the machine is hydraulic drive, and the hydraulic drive is selected to meet the technological requirements of synchronous roll movement when pre-bending and coiling plates, that is, the synchronous movement of the left and right sides of the roller movement process is automatically controlled by the PLC system without being affected by machining errors, mechanical wear failures and other factors, and after the pre-bending is completed, The two lower rollers can automatically return to the neutral position, to ensure that when rolling, because the two lower rollers are integral and symmetrically arranged, its horizontal force becomes internal force, the supporting force on the piston cylinder is very small, when the two lower rollers are moved horizontally, the upper roller does not exert pressure, it is only affected by the friction brought by the weight of the lower roller, plate, etc. In the structural arrangement, the horizontal movement mechanism is externally installed on the bed inside the frame, which is convenient for maintenance and adjustment, and at the same time makes the lower roller frame have a large space, which is convenient for installing and using rolling bearings, reducing energy loss, and easy to lubricate.
b. The horizontal moving guide rail of the two lower rollers is arranged under the frame, because the guide rail is compressed, the U-shaped guide rail is used and the axial radial positioning key is used to position, and the positioning is accurate; The guide rail structure is simple and the force is good. The lower roller horizontal movement mechanism is moved in a fixed frame structure, which has the advantages of good force, low center of gravity, and large axial force.
7-3. The frame structure of the machine
The frame of the machine is an integral frame structure, all working rollers, transmissions, etc. are installed on a base based on the frame, the overall rigidity is high, easy to install and use, especially the requirements for the foundation are low, adapt to the production requirements of strong mobility, and the relocation work is convenient.
7-4. Select the position of the main cylinder as the downward type
When the cylinder is lowered, the center of gravity of the whole machine is moved down, the center of gravity is low, the body is stable, the frame only bears the torque when coiling, the pouring bearing body is poured flexibly and quickly when the workpiece is removed, and the coil force acts on the overall base. Although the manufacturing cost has increased, the machine is stable in use, which is conducive to heavy-duty work.
8. Design, manufacture, installation and acceptance standards of horizontal downward bending machine
JB/T8796-1998 Bending Machine accuracy
JB/T1829-1997 General technical conditions for forging machinery
GB17120-1997 Safety technical conditions for forging machinery
JB/T8609-1997 Technical conditions for forging mechanical weldments
JB3623-84 Forging machinery noise measurement method
JB/ZQ4000.5 General technical conditions for castings
JB/ZQ4000.9 General technical conditions for assembly
JB/ZQ4000.10 General technical specifications for coating
GB3766-83 General technical conditions for hydraulic systems
GB16754-1997 Design principles for machinery safety emergency stop
GB/T5226.1-1996 Electrical equipment for industrial machinery - Part 1: General technical conditions
GB/T6402 Ultrasonic inspection method for steel forgings
9. Main standard part configuration
| No |
Name |
Manufacturer |
Note |
| 1 |
Work rollers |
Nangang |
|
| 2 |
Planetary gearbox |
Ningbo Zhongcheng |
|
| 3 |
Work roller bearings |
Wafangdian, Luoxian |
|
| 4 |
Displacement sensors |
Kaiser |
|
| 5 |
Hydraulic motor |
Ningbo Zhongcheng |
|
| 6 |
Hydraulic pump |
Qidong High Pressure, Hefei Changyuan |
|
| 7 |
Hydraulic valves |
Beijing Huade |
|
| 8 |
PLC control system |
Siemens |
|
| 9 |
display |
Kunlun Tong |
|
| 10 |
Main electrical components |
Schneider |
|
| 11 |
Cylinder sealing |
Guangji Institute |
|
| 12 |
Centralized lubrication system |
Bechil, Flow |
|
| 14 |
Motor |
Anhui entrepreneurship |
|
10. Production of main parts
This machine is a hydraulic CNC three-roll bending machine, the main parts are composed of frame and working rollers, etc.
10-1. Rack
(Rack) (CNC pentahedral machining center).
The Q235 steel plate is used as a whole welding structure, and the weld has undergone strict inspection, and the annealing treatment after welding has eliminated the internal stress.
The frame is the main force-bearing member of the machine, and the design has sufficient strength and rigidity to ensure the needs of the coil. The frame of the welded structure is machined by CNC machine tools to ensure its accuracy.
Rack machining technology:
Steel plate shot blasting treatment→ CNC cutting cutting→ groove → welding of each plate part→ integral annealing→ pentahedral machining center processing
10-2. Working roller
The working roller is the key working part of the machine, the working roller material is 42CrMo, and the overall quenching and tempering treatment is HB26 0-300.
(Upper working roller)
(lower roller).
(8000T forging machine).
(Heat treatment 12M pit furnace).
(CK61250A×25/80 CNC heavy duty horizontal lathe).
42CrMo steel belongs to ultra-high strength steel, with high strength and toughness, good hardenability, and no obvious tempering brittleness.
42CrMo allowable stress 186~310/MPa, yield point 930σs/MPa, 42CrMo strength, high hardenability, good toughness, small deformation during quenching, High creep strength and durable strength at high temperatures.
After quenching and tempering treatment, it has high fatigue limit and multiple impact resistance, and good low temperature impact toughness. The steel is suitable for the manufacture of large rolls that require certain strength and toughness.
Chemical composition
Carbon C: 0.38~0.45%.
Silicon Yes:0.17~0.37%
Manganese Mn:0.50~0.80%
Sulfur S: Permissible residual content ≤ 0.035%.
Phosphorus P: allowable residual content ≤ 0.035%.
Chromium Cr: 0.90~1.20%
Nickel Ni: allowable residual content ≤ 0.030%.
Cu: allowable residual content ≤0.030%.
Molybdenum Mo:0.15~0.25%
Work roll making process route
Cast ingots (chemical composition analysis) - Surface inspection - Forged blanks - Post-forging annealing - UT flaw detection - Rough machining - Heat treatment (tempering) - UT flaw detection - semi-finishing - finishing - MT
11. Scope of Supply
11-1. Supply
1) Host
2) Hydraulic equipment
3) Electronic control equipment
4) Lubricate the equipment
5) Anchor bolts and random attachments
6) Instruction manual (including circuit diagrams and schedules, basic diagrams, etc.).
7) Certificate of conformity, packing list, attachment schedule
11-2. Provided by the user
1) Infrastructure
2) Hydraulic oil and grease
3) Power supply primary side wiring
Extra tools
| NO |
Name |
Quantity |
Note |
| 1 |
Allen wrenches 3-19 |
1 set |
|
| 2 |
Live wrench 250 |
1 pc |
|
| 3 |
Pipe clamp 350 |
1 pc |
|
Spare parts
| NO |
Name |
Quantity |
Note |
| 1 |
Line seals |
2 sets |
|
| 2 |
button |
2 pcs |
|
| 3 |
Light |
2 pcs |
|
| 4 |
Micro relays |
2 pcs |
|
| 5 |
knob |
2 pcs |
|
| 6 |
Proximity switch |
2 pcs |
|
11. Installation and commissioning
After the equipment is shipped, the two parties will conduct an installation liaison coordination meeting, clarify the rights and obligations of both parties, and train or explain to the supplier personnel, covering installation and commissioning liaison, division of labor of acceptance personnel, on-site labor discipline, civilized construction, etc., clarify the contact person for on-site installation and commissioning of equipment between the two parties, and communicate various matters between the contact persons of both parties during the equipment installation and construction.
11-1. The demander shall carry out construction according to the foundation condition drawing provided by the supplier, and the construction drawing shall be carried out after the construction drawing is approved by both parties.
11-2. The demander is responsible for foundation construction, fence and cover plate production, and is responsible for hydraulic oil, gear oil and other oils for equipment operation.
11-3. The demander is responsible for equipment lifting, spreader and personnel cooperation.
11-4. During the installation and commissioning of the supplier's personnel, the demander needs to be equipped with 2-3 people to track the installation site, be familiar with the structure of the equipment and installation and maintenance methods, and recommend the operators and maintenance personnel of the equipment to track the whole process of installation and commissioning.
11-5. The supplier is responsible for equipment installation and commissioning, and is responsible for equipment precision control, and the demander personnel cooperate on site.
12. Installation and commissioning training and acceptance
12.1 Pre-acceptance
Ten days before the completion of the equipment production, B sends a pre-acceptance invitation letter to Party A. Party A formulates the pre-acceptance schedule and inspection list in advance, and Party A arrives at Party B's factory according to the time agreed by both parties and conducts pre-acceptance according to the schedule and list.
After all projects are accepted and qualified, both parties shall form a written record. All pre-accepted items and test data should be attended and signed by personnel from both parties, and at the same time for both parties to file.
12. 2. Final acceptance
The final acceptance of the equipment is carried out in Party A's factory, and the buyer and seller are accepted according to the standards, items and contents specified in the technical agreement and contract, and the acceptance content includes structure, configuration, performance, precision, efficiency, appearance quality, stability, etc., and the person in charge of both parties signs and confirms after qualifying, and the warranty period begins;
13. Delivery of documents
13-1. Provide detailed parameters such as equipment electricity and lubricating oil, as well as equipment basic drawings (CAD version) and equipment outline drawings (A1 paper + electronic version) within 20 days after the contract takes effect. Party B is responsible for its accuracy, and other information is provided randomly;
13-2. Equipment manual;
13-3. Provide factory certificate and precision test report;
13-4. packing list.
14. Quality assurance and after-sales technical services
14.1. When delivering, the production certificate, quality assurance cycle and other information of the key parts of the whole machine are required, and the quality of the materials and purchased components and components used in the bending machine should be reliable and meet the relevant standards.
14.2. The equipment warranty period is one year after the equipment acceptance, and Party B guarantees the bending machine for one year. If the equipment fails within the warranty period, Party B must respond positively within 8 hours after receiving Party A's notice, and if Party B needs to go to the site for processing, Party B must arrive at Party A's site within 48 hours.
14.3. During the warranty period and outside, Party A consults Party B about relevant technologies, and Party B shall carefully explain or provide information.
14.4. Outside the warranty period, due to the damage of the equipment caused by Party A's lack of use, Party B shall send someone to repair it, and the required expenses shall be paid by Party A.
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