I. Summarize:
- The equipment has the pre-bending function of the plate end and the CNC rolling function.
- It can feed the metal plate at a time, and can complete the pre-bending and the roll forming of the workpiece without turning the head.
- The upper working roll of the machine is the main drive roll, and the lower roll and both sides of the roll are hydraulically driven.
- The lift displacement is controlled by the computer and is automatically leveled.
- The screen display shows the synchronization accaccuracy of ±0.2mm.
- The tilting and resetting of the rollover bearing body is hydraulic transmission, the balance of the upper roll is equipped with a balance mechanism, which can easily take out the rolled workpiece.
- It has a mobile stand-alone console that can be moved at any time; the machine is equipped with a safety interlocking device and is safe.
- Due to its full-featured, high-precision, and easy-to-use operation, this device is the ideal contemporary CNC coiling device. It is the ideal model for rolling circular and arc-shaped workpieces in energy, transportation, petroleum, chemical, boiler, shipbuilding, hydropower, and metal structure industries.
II. The Main Structure:
1.Drop end cylinder 2.Drop end 3.Left frame 4.Upper roll 5.Side roll 6.Lower roll 7.Right frame 8.Balancing system 9.Upper roll driven device 10.Lower roll driven device【optional】 11.Side roll cylinder 12.Lower roll cylinder 13.Bottom frame 14.Side support system【optional】 15.Top support system【optional】 16. Electric feeding electric roll【optional】 17.Hydraulic system 18.Electronic control system
1) The working roll
One of the most important components of the rolling machine, its quality and performance has a direct impact on the service life of the rolling machine and the precision of rolling.
(1) Material of working roll
Working rolls are made of high-strength high-quality steel 42CrMo material, after forging,
roughing, quenching and tempering, HB240 ~ 300, finishing after the intermediate frequency quenching HRC45-55, according to JB/ZG4289-86 roll steel standards, the stiffness is consistent (1/700 ~1/1000) L. L——The distance between the centerlines of the sides rack. And strictly in accordance with the working process of manufacturing all the standard roll manufacturing, to ensure its comprehensive mechanical properties.
(2) Working Roll Rotation
Working Roll Rotation: Hydraulic Motor
Planetary Gearbox
Working Roll
The upper roll is a driving roll of four roll rolling machine (as shown below).
The independent hydraulic motor on the upper roll and the high-power box are directly coupled(straight), not through the intermediate gear transmission, which is the most energy-saving drive method. The hydraulic motor is equipped with an immediate brake to allow the roll to stop accurately in the pre-bending state.
(3) Working roll movement
According to the movement method of the working roll (side roller) of the rolling machine, the linear slide technology is adopted. The oil cylinder adopts an inverted oil cylinder, which greatly increases the contact area between the slider and the slide rail, and improves the stability and the rolling precision of the machine tool.
2)Bearing at both ends of the working roll
All work rolls have two roller bearings at each end, and the roller bearings are made of domestic famous brand products – Wafangdian bearings.
Each roller of the four roll machine is equipped with a highly durable self-aligning roller bearing recommended by the industry, which can effectively counteract the pressure caused by shaft deviation during the rotation of the roller shaft. Due to the free and flexible movement of each axis, the risk of scratches and cracks on the rollers is avoided. The internal design of this adjustable center bearing allows it to withstand the offset and tilt of the roller shaft. When it bears the force of a fixed outer cover, this
The foldable activity avoids damage to the roller shaft caused by reverse force.
The advantage of this type of bearing is that it can move smoothly and safely along the inclination of the roller shaft, regardless of its position, and eventually return to its original position. The requirements for conical coils are much more stringent, as they require the roller shaft to be able to tilt, which makes it difficult to balance the load on the roller shaft. It brings a lot of pressure to the bearing. With the use of adjustable center bearings, it can put this load into the “axial” mode, effectively controlling the impact of folding and enabling smooth and safe self rotation. Our company uses two adjustable center bearings on each roller shaft and adopts “permanent lubrication technology” throughout the entire service life of the product, eliminating the need for frequent lubrication of the bearings.
3) Rack and base
The base and frame are the main parts of the equipment. Our company selects high-quality
steel, uses CNC cutting, grinding and welding, and then sends the welded structural parts to the professional heat treatment factory for stress relief annealing — CNC lathe
machining, eliminating welding stress, so that it has enough strength and stiffness, to ensure normal operation at full load. All records of the workpiece are included in the quality tracking system.
4) Hydraulic system
Each oil circuit is routed with two relief valve to control pressures. The maximum set pressure for each oil circuit is 19 MPa, which is mainly to control the main cylinder pressure, and the other relief valve is set to 16 MPa, mainly to control the overturning cylinder and balancing cylinder pressure.
In order to ensure the synchronization accuracy of the main oil cylinders at both ends of each moving working roll, high-precision displacement sensors are installed on the left and right racks and the tilting frames. Through the pressure sensors, the microcomputer control system detects and adjusts the movements of the main oil cylinder pistons to achieve the precison of the both working roll ends.
Advantage of our hydraulic system:
- The unique pre-discharge technology is adopted to effectively avoid hydraulic shock and improve the life of the pipeline and seal.
- The hydraulic components are selected YUKEN quality products to ensure the stability of the hydraulic system.
- Each input and output port of the hydraulic system is provided with corresponding detection points, which are convenient for maintenance and fault checking. The oil pump adopts a lower-mounted type and positive pressure oil absorption. At the same time, the filters, level gauges, and all transmitting devices can automatically warn of faults.
- The system is manufactured strictly in accordding to national standards and industry standards. The radius of the tube is reasonable, and the radius is not less than 90°. The transition is smooth and the damper tube clamps are properly arranged, which effectively avoids shock and vibration. Make sure that there is no shock or vibration in the hydraulic circuit.
- The system design fully considers the high efficiency and energy saving, reduces the power waste, and reduces the heat source.
- The hydraulic oil pump and motor set are equipped with a special shock absorbing pad, and the oil suction port is equipped with a shock absorbing throat.
- Provide the test report of the main oil cylinder. System production strictly perform the national standards, and the proper connection point adopts a special sealant. Avoid leakage.
- Provide common fault phenomena and elimination methods for the hydraulic system of rolling machine.
- To ensure the manufacturing quality of the hydraulic system, the system is manufactured according to hydraulic professional manufacturers and the national GB3766-83 “General technical conditions for hydraulic systems.”
Gripping pressure can be set:
For different product rolling process requirements, the clamping force between the upper and lower rolls can be set in advance to effectively prevent excessive pressure on the softer material.
The clamping force is controlled by the hydraulic station relief valve.
5) Hydraulic system(CNC control system)
- The micro-control system includes the main electrical cabinets, control cabinets and other hardware components and special control software.
- Main Specifications:
Mean time between failures: ≥ 20000 hours
Display accuracy: ≤±0.2mm
When the lower roll is lifted and the side roll is inclined and lifted and the displacement is
synchronously controlled, the synchronization accuracy is: ≤±0.2mm
Sensor displacement resolution: ≤0.1mm
- The core components of the micro-control system
- CNC control system
Our company’s control system is equipped with an automatic rolling program, which can realize one-button operation. It can automatically roll and roll once at a time. It also has data number, storage and recall functions, and can store hundreds of data. Various specifications of automated rolling. The system is compatible with manual operation programs and can be manually operated when needed.
6)The processes of rolling board
