China Origin High-Performance roll forming machine
Application field
The W11NC series Marine Plate Rolling Machine is the epitome of engineering excellence, primarily designed for rolling circular plates such as ship shells and pressing groove-type bulkheads. Tailored to meet specific customer requirements, this versatile machine can be configured as either a symmetrical or asymmetrical three-roll coiling machine. The upper roller is supported by a robust rigid beam, while multiple sets of rollers are strategically placed between the upper roller, the beam, and the lower roller. This sophisticated arrangement ensures enhanced stiffness and precision for the upper and lower rollers, delivering impeccable performance through its full three-roller drive system.
| 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) |
Explore the Diverse Types of Marine Plate Rolling Machines:
1. Symmetrical Up-Mode: The upper work roller can perform 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, and the lower work roller translates horizontally.
3. Lower Rollers Horizontal Adjustment: The upper rollers lift vertically as the lower rollers move horizontally.
4. Roller Universal Mode: The upper work roller can lift vertically and translate horizontally while the positions of the two work rollers stay unchanged.
(The upper roller can be adjusted both vertically and horizontally)
CNC 4 Roll Hydraulic Steel Plate Bending Machine - Advanced Sheet Metal Bender Roller
Additionally, we offer a comprehensive Pipeline Rolling Production Line:
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 robust machine is primarily designed to bend metal sheets of varying thicknesses into cylindrical, arc, rectangular, or other intricately curved shapes. It is an indispensable piece of equipment across a wide range of industries, including metallurgy, construction materials, petroleum, chemicals, hydropower, bridges, defense, coal, mining, shipbuilding, boilers, aviation, and the manufacturing of electrical transmission and transformation equipment.
Our state-of-the-art machine features a main driving upper roller, equipped with pre-bending and CNC rolling functions specifically for the end portions of metal sheets. It allows a single feed of the metal sheets, 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 comes with an instant brake, facilitating precise stopping during the bending and rolling processes. The lifting and lowering of the lower and side rollers are hydraulically driven, with displacement controlled by an advanced computer system. The displacement of the rollers can be directly monitored through a CRT display using encoders for detection. This machine stands out for its simple operation, unparalleled convenience, and exceptional efficiency.
Our machine boasts automatic leveling, 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 effortless removal of the rolled workpiece and cylinder. It also includes a movable, independent operating platform for flexible movement. Safety is paramount, with built-in safety interlock devices ensuring secure operations.
3PHASE AC
380V±20, 50Hz±5Hz
Temperature Range: -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 basic structural components of the machine 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 machine is constructed with left and right frames mounted on a unified base, forming the core structure. 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 securely installed within the right frame.
The upper roller functions as the primary driving force of the machine. It is directly linked to the hydraulic motor via a sophisticated planetary gearbox. Remaining stationary in its position, the upper roller engages only in rotational motion. In contrast, the working roller is dynamically involved in both rotational and vertical movements, executing precise lifting and lowering actions.
The lower and side rollers are maneuvered by oil cylinders positioned within the guide grooves on the left and right frames. This design allows for the precise upward and downward movement, as well as tilting of the rollers. Such flexibility is pivotal for rolling conical workpieces and ensuring the correction and rounding of all workpieces. The left frame houses a flipping bearing mechanism, operated by an oil cylinder, facilitating smooth interaction with the upper roller's head. Additionally, a balancing device at the tail end of the upper roller ensures equilibrium and assists in lifting when the upper roller is open. High-quality linear slide rails guide the working roller's motion, ensuring impeccable precision.
The entire machine's control system is seamlessly centralized on the main operating console.
3.1.1 Work rollers
As a vital component of the rolling machine, the work rollers directly influence the machine's longevity and the precision of the rolling process.
(1)Roller materials
Engineered from high-strength rolling steel, the working rollers undergo extensive procedures including forging, tempering, quenching, stress relief, and precision lathe machining. These processes ensure superior surface contact strength, crucial for preventing surface impressions during steel plate rolling. This meticulous manufacturing guarantees the rollers' durability and their ability to meet long-term rolling demands while maintaining optimal mechanical performance. Following rough processing, the rollers are tempered to achieve a hardness of HB240
~
300. Subsequent precision processing involves intermediate frequency quenching, resulting in a final hardness of HRC45-55, adhering to the JB/ZG4289-86 rolling steel standard. The stiffness ratio is meticulously maintained within (1/700-1/1000) L, where L represents the distance between the centerlines of the two side frames.
(2) The rotation of the work roller: torque is efficiently transmitted from the hydraulic motor, through the planetary gearbox, directly to the work roller.
The four-roller rolling machine operates with the upper roller as the driving force. This roller is independently powered by a high-power hydraulic motor, directly coupled to a high-efficiency planetary gearbox, eliminating the need for intermediate gears. This setup maximizes energy efficiency. The hydraulic motor features an instant brake system, ensuring precise stoppage of roller rotation during the pre-bending process.
Schematic diagram of upper rollAdjustable clamping pressure:
To cater to diverse rolling processes, the clamping force
between the upper and lower rollers can be preset, thereby effectively preventing
overpressure indentation on softer materials.
The clamping force is meticulously regulated by the hydraulic station's relief valve.
3.1.2Bearings at both ends of the work rollers
Each end of every working roller is equipped with two roller bearings, crafted by Wafangdian shafts, a renowned brand in China.
Each roller in our state-of-the-art four-roller machine is equipped with industry-recommended, highly durable self-aligning roller bearings. These bearings effectively counteract pressure caused by shaft misalignment during roller operation, ensuring smooth and flexible movement. This advanced design prevents scratches and cracks on the rollers. The internal engineering of these bearings allows them to withstand misalignment and tilt, while the foldable mobility feature protects the roller shaft from damage due to reverse forces, even under fixed outer cover pressures.
The advantages of our self-aligning bearings are unparalleled. No matter how the roller shaft deviates, it can smoothly and safely return to its original position. Conical rolling demands that the roller shaft tilts, imposing an unbalanced load and significant pressure on the bearings. Our bearings channel this load into an 'axial' mode, effectively managing the impact and allowing for smooth, safe self-rotation. Each roller shaft in our machinery utilizes two self-aligning bearings with 'permanent lubrication technology,' ensuring a maintenance-free lifespan.
3.2.1Racks and bases
The frame and seat of our coilers are crafted from premium Q235A/Q345 high-quality steel, sourced domestically, and CNC
machine cut
, polished, and expertly welded. Post-welding, these structural parts are sent to a specialized heat treatment facility for stress relief annealing and CNC lathe machining. Comprehensive records of each workpiece are maintained in our quality tracking system.
3.3.1Hydraulic system
Our hydraulic system boasts an independent hydraulic circuit with two main functions. The primary section drives the upper and lower working rollers, while the auxiliary section handles the lifting and lowering of the lower and side rollers and provides power for the tilting frame. Each circuit is powered by a high-pressure oil pump driven by an electric motor, utilizing a superimposed valve structure. Key features include:
Reducing device and installation space
Quick and easy expansion or modification of the hydraulic system without special installation skills.
Avoidance of diverter valve synchronous systems, eliminating issues from inconsistent pressure between cylinders,
Enhanced reliability through the prevention of leakage, vibration, and noise during pipeline connections;
Stacked components for easy maintenance and inspection.
Each hydraulic circuit is managed by two relief valves to regulate pressure. The primary relief valve, set at 20MPa, controls the main cylinder pressure, while a secondary valve at 16MPa manages the tilting and balancing cylinders.
In every hydraulic circuit, the main cylinder employs two sets of stacked components to adjust movement speed, accommodating different working speeds for the side and lower rollers in various conditions.
High-precision displacement sensors are installed on the left and right frames and the tilting frame to ensure synchronization accuracy of the main cylinders at both ends of each moving working roller. These sensors, coupled with pressure sensors and a microcomputer control system, monitor and adjust the displacement of the main cylinder pistons to meet synchronization accuracy requirements.
a,
Our unique pre-unloading pressure technology effectively prevents hydraulic shock, thus extending the lifespan of pipelines and seals.
b,Hydraulic components are sourced from top-quality 'Yuyan' products, guaranteeing the stability and reliability of our 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.
3.4.1Lubrication 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 an unforeseen circumstance, operators can swiftly and effortlessly shut down the equipment and system, ensuring the utmost safety for both the machinery and personnel.
Control Function:
The industrial computer seamlessly communicates with the Siemens PLC via a dedicated communication cable, acquiring critical data such as the displacement of the front and rear side rollers, and the PLC's input/output status.
With the integration of the aforementioned data, the computer and PLC intelligently process and control the PLC's output. Through the use of intermediate relays, they manage peripheral devices, motor operations, and hydraulic valve switching, ensuring the smooth and optimal functioning of the control system.
3.6.1 Embedded Software for CNC 4 Roll Hydraulic Steel Plate Bending Machine Sheet Metal Bender Roller
The machine features a user-friendly interface that allows batch rolling data to be invoked with just a single click. Our advanced control system software includes an automatic rolling program, enabling one-click operations for data collection, calibration, storage, invocation, and post-calibration startup.
In automatic mode, the system can autonomously feed the material and complete a one-time circular forming process. The software also offers capabilities for data numbering, storage, and retrieval, accommodating data for hundreds of specifications. This facilitates efficient automated rolling for various sizes. Additionally, the system is compatible with manual operation programs, allowing for a seamless switch to manual operation when required.
The software not only supports the automatic rolling of circular workpieces but also extends its capabilities to the automated rolling of non-circular shapes, including square workpieces, ensuring versatile functionality.
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 CNC 4 Roll Hydraulic Steel Plate Bending Machine Sheet Metal Bender Roller is meticulously packaged and loaded with care for optimal protection during transit.
Our high-quality goods are sought after and sold all over the world, showcasing their global appeal and reliability.
We warmly welcome customers to visit our factory, where they can witness firsthand the precision and excellence of our manufacturing process.
Our Honors:
Nanjing Yunyan Digital Technology Co., Ltd is proud to serve as the exporting arm of Jiangsu Yizhong CNC Machine Tool (Group) Co., Ltd.
Our esteemed group, a prestigious leader among China's machine tool factories, was established in 2006 and is strategically located in the Chengbei industrial area of Yangzhou city, Jiangsu province. Spanning a vast 498,700 square meters and boasting nine state-of-the-art production lines, we are recognized as a National Torch Plan and High-Tech enterprise.
Our extensive product range includes 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. With our robust technician team, we excel in OEM machine production, delivering bespoke solutions tailored to your needs.
Over years of dedicated effort, we have cultivated enduring, close-knit partnerships with clients across the globe, including Russia, Australia, the United Kingdom, Italy, South America, Egypt, India, and beyond. We warmly welcome your inquiries and look forward to collaborating with you.
After service:
The warranty period extends for 12 months, beginning from the date of successful installation and trial operation, ensuring peace of mind and reliability.
The equipment supplied by the seller is brand new and unused. Upon installation, debugging, and operation, the performance of this equipment will meet or exceed the relevant national standards or the terms stipulated in the agreement between both parties.
The seller commits to providing prompt technical support within 2 hours after receiving a call from the buyer. Should the buyer be unable to resolve the issue independently, the seller will perform troubleshooting within 24 hours within the seller's country. Any parts identified as having quality-related issues during the warranty period will be replaced free of charge, ensuring continuous operation.
Our team of professional technicians is available for installation and training at the customer's factory, offering expertise and guidance for just a reasonable labor fee.
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