Upper Roll Universal Plate Rolls Machine
Overview
This machine is a hydraulic three-roll plate rolling machine, which is used to roll the steel plate into a cylindrical shape at room temperature.
The upper roll can move vertically and horizontally.
Pre-bending is achieved by moving the upper roll horizontally so that the upper roll is in an asymmetrical position relative to the lower roll.
Since the elevation of the lower roll remains unchanged, it is convenient to feed and operate.
The hydraulic components used in the equipment adopt famous brand products; adopt PLC programmable display control.
The equipment runs smoothly, with flexible control, no jamming, oil leakage and abnormal noise, high reliability and low failure rate.
The tipping frame adopts hydraulic tipping, the vertical displacement of the upper roll adopts hydraulic transmission, and the horizontal movement adopts mechanical transmission.
1. The characteristics of the upper roll universal bending machine
1.%2. The upper roll universal bending machine is considered to be the most versatile, cost-effective, and easiest to use bending equipment.
1.2. The position of the lower roll is fixed to ensure the accuracy of the position after the plate is loaded.
1.3. The tilt adjustment of the upper roll is very convenient for correcting defects such as wrong sides of the reel.
1.4. The upper and lower rolls clamp the steel plate, and there is no relative sliding phenomenon during the rolling process.
1.5. The flat steel plate is clamped by the upper and lower rolls, so that the pre-bending and coiling operations can be carried out safely and accurately without the risk of slipping off the plate.
1.6. There is no need to tilt the plate below the working surface during pre-bending operation.
1.7. Once the edge of the plate head is pre-bent, it can be rolled into a cylinder, and the plate cylinder can be rolled on one side of the machine tool, which means that the area of the workshop occupied by the equipment is small.
1.8. The drum-shaped upper roll is matched with the adjustable idler roll to complete the precision guarantee of the plate rolling.
1.9. After pre-bending the edge of one plate head of the cylinder, the tail plate head can be directly curled.
1.10. The left and right leveling accuracy of the upper roll lifting is ±0.2mm.
1.11. The three-roll plate bending machine is more convenient and easy to operate.
1.12. The hydraulic system of the equipment is equipped with overpressure protection, and the electrical system has circuit breakers for overcurrent protection, overheating, and thermal relays for overload protection. When a fault occurs, a fault indicator will indicate. There is safety interlock protection between the main actions of the equipment.
2. The main structure
The main structure of the equipment is composed of upper roll device, lower roll and upper roll horizontal movement device, supporting roll device, main transmission device, overturning device, left and right side frame, chassis and balance device.
3.1. Upper roll device and horizontal moving device
The upper roll device is composed of main oil cylinder, upper roll bearing seat, upper roll, double row self-aligning bearing, etc.
The two main oil cylinders provide the pressurizing pressure required to roll the plate, and the working pressure of the main oil cylinder is 19.5 MPa.
The double-row self-aligning bearings adopt low-speed, heavy-duty spherical roll bearings.
The upper roll is in the shape of a drum, and the load coefficient of the maximum pressure of the upper roll is 0.7 uniformly distributed load to preset and compensate the deformation and deflection of the upper roll.
The upper roll is made of alloy steel 42CrMo, after rough machining, quenched and tempered, HB260~300, in accordance with JB/ZG4289-86 roll steel standard, rigidity in line with (1/700~1/1000) LL—refers to the center line of the two sides of the rack The distance between.
The upper roll horizontal moving device is powered by a horizontal moving motor, and the upper roll device is driven to move horizontally through the worm gear box, worm gear, and screw nut mechanism to realize asymmetrical rolling of the plate.
(Upper roll device)
3.2. Lower roll device
The lower roll device is composed of the lower roll, the lower roll bearing seat, the lower roll input gear, and the lower roll sliding bearing.
The material of the bottom roll is 45, after roughing and quenching and tempering, HB260~300, in accordance with JB/ZG4289-86 roll steel standard, rigidity in line with (1/700~1/1000) LL—refers to the distance between the center lines of the two sides of the rack .
SF-1 self-lubricating composite material is selected for the lower roll sliding bearing.
The main drive of the lower roll provides power through the main drive output gear, the lower roll input gear, and the open transmission torque to the lower roll.
(Bottom roll and upper roll horizontal movement device)
3.3. roll device
The roll device is composed of roll, worm gear mechanism, oblique wedge mechanism, etc.
The roll is made of 45 steel, quenched and tempered, and the hardness is HB190~220. The surface hardness of the roll is lower than that of the lower roll, and the surface is turned with spiral grooves, which effectively prevents the oxide scale and impurities of the lower roll from damaging the working surface of the lower roll. .
There are four rolls in each group, which can be adjusted up and down according to the load size of the rolled sheet specification.
3.4.The main transmission device
The main transmission device is composed of a main motor, a cylindrical gear reducer, an electro-hydraulic push rod brake, etc. The output gear drives two lower roll gears. The main drive can be forward and reverse to provide the rolling torque for the rolling of the plate.
3.5.Tipping device
The tipping device is composed of a ram, a tipping cylinder, etc.
The piston rod of the overturned cylinder is chrome-plated.
The overturning of the overturning device facilitates the removal of the product along the axial direction of the roll.
(Tipping device)
3.6. Tixed, overturned side frame, chassis
The fixed and overturned side frame and chassis are welded parts of steel plates, which are annealed after welding to remove stress and shot peened.
The fixed, overturned side frame is used to house the two main cylinders.
The chassis adopts a frame structure, with high torsion section coefficient, few anchor bolts, and convenient installation and debugging.
4.Hydraulic system
4.1. General overview
The hydraulic system consists of gear pumps, valve blocks, fluid connections, hydraulic accessories, etc.
The hydraulic valve adopts superimposed valve series, with simple pipeline layout and convenient maintenance and debugging.
The system consists of three circuits, overpressure protection and pressure regulation circuit, synchronization circuit and speed circuit.
The pressure regulating circuit regulates the working pressure of the system through the main relief valve. The working pressure of the system is 19.5MPa.
Synchronous circuit uses a shunt throttle valve to synchronize the rising and falling coarse steps of the upper roller, and the throttle valve adjusts up and down; the displacement sensor detects that the synchronization positioning accuracy of the upper roller is ±0.15mm.
The speed loop controls the overturning and resetting of the machine on the overturned side, and adjusts the loop throttle speed through the throttle valve.
4.2. various protections
The rising and falling of the upper roller are respectively provided with overflow valves for pressure limit protection.
5.Electrical control system
5.1. General overview
The electrical control system of the equipment consists of an electrical control cabinet, an operating console, and a hand-held button box.
Main technical indicators of the system
The working voltage of the system is 380V 50Hz;
The ambient temperature is -5℃~45℃;
The control circuit adopts PLC programmable controller system, with few relays, reliable action and long life.
The control cabinet is equipped with all control buttons, indicator lights, programmable displays, etc. to complete the product rolling process to control the operation of the whole machine.
5.2. various protections
Each motor has a corresponding circuit breaker for over-current short-circuit protection;
Each motor has a corresponding thermal relay for overload protection;
The horizontal movement of the upper roller has corresponding limit switches for limit protection;
The overturning and resetting of the overturning cylinder are respectively provided with upper and lower limit switch limit protection;
The main power circuit breaker has a shunt release, and there is an "emergency stop" button on the console and portable button box to cut off the main power remotely.
5.3. various interlocks
After the overturning frame is fully reset, the upper roller lifting, moving forward and backward, and the lower roller forward and backward can be carried out ("the overturning frame reset" is detected by the limit switch);
When the upper roller is in the upper position, the upper roller moves horizontally, and the overturned side drops alone cannot be performed (the "upper roller upper position" limit switch is used for detection);
When the working pressure of the upper roller pressure relay is greater than 1/3P, the upper roller cannot move back and forth (the pressure relay is used for detection).
5.4. Fault indication
When the lower roller motor and the horizontal moving motor, the fault indicator shows;
When PLC fails, the fault indicator will prompt.
6. Control system general overview
The electrical control system of the equipment consists of an operation console and a handheld button box.
The power supply is three-phase four-wire system 380V/50Hz.
The control circuit adopts PLC programmable controller system, with few relays, reliable action and long life.
The control cabinet is equipped with all control buttons and indicator lights to complete the rolling process of the product to monitor and control the rolling working status of the whole machine.
7. The technical characteristics of the upper roller universal bending machine
7.1. Adjusting the idler under the lower roller greatly improves the straightness of the product.
7.1.1.Rolling thick plate situation
For thick plates, the support of the lower roll is adjusted upward.
Product shape
The t value is very small, and the product has high straightness.
7.1.2.Rolling thin plate situation
For thin plates, the support of the lower roll is adjusted down
Product shape
It is impossible to appear "beam-shaped" and the product has high straightness.
8. Rolling process
8.1.When roll a sheet, first the machine bends the end part, then carries out symmetry bend according to picture below.
8.1.1.Bend the end part
(1) Let upper roller go up for a distance.
(2) Upper roller moves left or right to clip the plate tightly.
(3) Upper roller drops
(4) Drive lower roller
(5) The same course
8.1.2.Symmetry bend
(1) Adjust upper roller ( symmetrical to lower roller ), then put in the steel.
(2) Start the left and right oil cylinders and add pressure to make upper roller press the steel which drives lower roller to bend steel.
(3) Add pressure gradually and drive rollers to rotate again and again. The bend is done.
8.1.3. Unload material
(1) Move upper roller to the location of central high limit, others don’t move, at this time, the upper roller is in balance.
(2) Overturn frame turns over to unload material.
(3) Overturn frame resets.
8.2.When roll circular arc work pieces, normally we first bend the end part.
8.2.1.Shown as diagram below, upper roller moves to one side and be adjusted to correspond height. Firstly, bend the end part.
8.2.2.Rotate work rollers, take central parts’ bending.
8.2.3.Work rollers reverse.
8.2.4.Upper roller goes up and moves to the other side.
8.2.5.Upper roller drops to correspond height which drives work rollers to bend surplus part of central area.
8.2.6.At last, bend end part of the other side.
End part bend
Symmetry bend
Upper Roll Universal Plate Rolls Machine
Overview
This machine is a hydraulic three-roll plate rolling machine, which is used to roll the steel plate into a cylindrical shape at room temperature.
The upper roll can move vertically and horizontally.
Pre-bending is achieved by moving the upper roll horizontally so that the upper roll is in an asymmetrical position relative to the lower roll.
Since the elevation of the lower roll remains unchanged, it is convenient to feed and operate.
The hydraulic components used in the equipment adopt famous brand products; adopt PLC programmable display control.
The equipment runs smoothly, with flexible control, no jamming, oil leakage and abnormal noise, high reliability and low failure rate.
The tipping frame adopts hydraulic tipping, the vertical displacement of the upper roll adopts hydraulic transmission, and the horizontal movement adopts mechanical transmission.
1. The characteristics of the upper roll universal bending machine
1.%2. The upper roll universal bending machine is considered to be the most versatile, cost-effective, and easiest to use bending equipment.
1.2. The position of the lower roll is fixed to ensure the accuracy of the position after the plate is loaded.
1.3. The tilt adjustment of the upper roll is very convenient for correcting defects such as wrong sides of the reel.
1.4. The upper and lower rolls clamp the steel plate, and there is no relative sliding phenomenon during the rolling process.
1.5. The flat steel plate is clamped by the upper and lower rolls, so that the pre-bending and coiling operations can be carried out safely and accurately without the risk of slipping off the plate.
1.6. There is no need to tilt the plate below the working surface during pre-bending operation.
1.7. Once the edge of the plate head is pre-bent, it can be rolled into a cylinder, and the plate cylinder can be rolled on one side of the machine tool, which means that the area of the workshop occupied by the equipment is small.
1.8. The drum-shaped upper roll is matched with the adjustable idler roll to complete the precision guarantee of the plate rolling.
1.9. After pre-bending the edge of one plate head of the cylinder, the tail plate head can be directly curled.
1.10. The left and right leveling accuracy of the upper roll lifting is ±0.2mm.
1.11. The three-roll plate bending machine is more convenient and easy to operate.
1.12. The hydraulic system of the equipment is equipped with overpressure protection, and the electrical system has circuit breakers for overcurrent protection, overheating, and thermal relays for overload protection. When a fault occurs, a fault indicator will indicate. There is safety interlock protection between the main actions of the equipment.
2. The main structure
The main structure of the equipment is composed of upper roll device, lower roll and upper roll horizontal movement device, supporting roll device, main transmission device, overturning device, left and right side frame, chassis and balance device.
3.1. Upper roll device and horizontal moving device
The upper roll device is composed of main oil cylinder, upper roll bearing seat, upper roll, double row self-aligning bearing, etc.
The two main oil cylinders provide the pressurizing pressure required to roll the plate, and the working pressure of the main oil cylinder is 19.5 MPa.
The double-row self-aligning bearings adopt low-speed, heavy-duty spherical roll bearings.
The upper roll is in the shape of a drum, and the load coefficient of the maximum pressure of the upper roll is 0.7 uniformly distributed load to preset and compensate the deformation and deflection of the upper roll.
The upper roll is made of alloy steel 42CrMo, after rough machining, quenched and tempered, HB260~300, in accordance with JB/ZG4289-86 roll steel standard, rigidity in line with (1/700~1/1000) LL—refers to the center line of the two sides of the rack The distance between.
The upper roll horizontal moving device is powered by a horizontal moving motor, and the upper roll device is driven to move horizontally through the worm gear box, worm gear, and screw nut mechanism to realize asymmetrical rolling of the plate.
(Upper roll device)
3.2. Lower roll device
The lower roll device is composed of the lower roll, the lower roll bearing seat, the lower roll input gear, and the lower roll sliding bearing.
The material of the bottom roll is 45, after roughing and quenching and tempering, HB260~300, in accordance with JB/ZG4289-86 roll steel standard, rigidity in line with (1/700~1/1000) LL—refers to the distance between the center lines of the two sides of the rack .
SF-1 self-lubricating composite material is selected for the lower roll sliding bearing.
The main drive of the lower roll provides power through the main drive output gear, the lower roll input gear, and the open transmission torque to the lower roll.
(Bottom roll and upper roll horizontal movement device)
3.3. roll device
The roll device is composed of roll, worm gear mechanism, oblique wedge mechanism, etc.
The roll is made of 45 steel, quenched and tempered, and the hardness is HB190~220. The surface hardness of the roll is lower than that of the lower roll, and the surface is turned with spiral grooves, which effectively prevents the oxide scale and impurities of the lower roll from damaging the working surface of the lower roll. .
There are four rolls in each group, which can be adjusted up and down according to the load size of the rolled sheet specification.
3.4.The main transmission device
The main transmission device is composed of a main motor, a cylindrical gear reducer, an electro-hydraulic push rod brake, etc. The output gear drives two lower roll gears. The main drive can be forward and reverse to provide the rolling torque for the rolling of the plate.
3.5.Tipping device
The tipping device is composed of a ram, a tipping cylinder, etc.
The piston rod of the overturned cylinder is chrome-plated.
The overturning of the overturning device facilitates the removal of the product along the axial direction of the roll.
(Tipping device)
3.6. Tixed, overturned side frame, chassis
The fixed and overturned side frame and chassis are welded parts of steel plates, which are annealed after welding to remove stress and shot peened.
The fixed, overturned side frame is used to house the two main cylinders.
The chassis adopts a frame structure, with high torsion section coefficient, few anchor bolts, and convenient installation and debugging.
4.Hydraulic system
4.1. General overview
The hydraulic system consists of gear pumps, valve blocks, fluid connections, hydraulic accessories, etc.
The hydraulic valve adopts superimposed valve series, with simple pipeline layout and convenient maintenance and debugging.
The system consists of three circuits, overpressure protection and pressure regulation circuit, synchronization circuit and speed circuit.
The pressure regulating circuit regulates the working pressure of the system through the main relief valve. The working pressure of the system is 19.5MPa.
Synchronous circuit uses a shunt throttle valve to synchronize the rising and falling coarse steps of the upper roller, and the throttle valve adjusts up and down; the displacement sensor detects that the synchronization positioning accuracy of the upper roller is ±0.15mm.
The speed loop controls the overturning and resetting of the machine on the overturned side, and adjusts the loop throttle speed through the throttle valve.
4.2. various protections
The rising and falling of the upper roller are respectively provided with overflow valves for pressure limit protection.
5.Electrical control system
5.1. General overview
The electrical control system of the equipment consists of an electrical control cabinet, an operating console, and a hand-held button box.
Main technical indicators of the system
The working voltage of the system is 380V 50Hz;
The ambient temperature is -5℃~45℃;
The control circuit adopts PLC programmable controller system, with few relays, reliable action and long life.
The control cabinet is equipped with all control buttons, indicator lights, programmable displays, etc. to complete the product rolling process to control the operation of the whole machine.
5.2. various protections
Each motor has a corresponding circuit breaker for over-current short-circuit protection;
Each motor has a corresponding thermal relay for overload protection;
The horizontal movement of the upper roller has corresponding limit switches for limit protection;
The overturning and resetting of the overturning cylinder are respectively provided with upper and lower limit switch limit protection;
The main power circuit breaker has a shunt release, and there is an "emergency stop" button on the console and portable button box to cut off the main power remotely.
5.3. various interlocks
After the overturning frame is fully reset, the upper roller lifting, moving forward and backward, and the lower roller forward and backward can be carried out ("the overturning frame reset" is detected by the limit switch);
When the upper roller is in the upper position, the upper roller moves horizontally, and the overturned side drops alone cannot be performed (the "upper roller upper position" limit switch is used for detection);
When the working pressure of the upper roller pressure relay is greater than 1/3P, the upper roller cannot move back and forth (the pressure relay is used for detection).
5.4. Fault indication
When the lower roller motor and the horizontal moving motor, the fault indicator shows;
When PLC fails, the fault indicator will prompt.
6. Control system general overview
The electrical control system of the equipment consists of an operation console and a handheld button box.
The power supply is three-phase four-wire system 380V/50Hz.
The control circuit adopts PLC programmable controller system, with few relays, reliable action and long life.
The control cabinet is equipped with all control buttons and indicator lights to complete the rolling process of the product to monitor and control the rolling working status of the whole machine.
7. The technical characteristics of the upper roller universal bending machine
7.1. Adjusting the idler under the lower roller greatly improves the straightness of the product.
7.1.1.Rolling thick plate situation
For thick plates, the support of the lower roll is adjusted upward.
Product shape
The t value is very small, and the product has high straightness.
7.1.2.Rolling thin plate situation
For thin plates, the support of the lower roll is adjusted down
Product shape
It is impossible to appear "beam-shaped" and the product has high straightness.
8. Rolling process
8.1.When roll a sheet, first the machine bends the end part, then carries out symmetry bend according to picture below.
8.1.1.Bend the end part
(1) Let upper roller go up for a distance.
(2) Upper roller moves left or right to clip the plate tightly.
(3) Upper roller drops
(4) Drive lower roller
(5) The same course
8.1.2.Symmetry bend
(1) Adjust upper roller ( symmetrical to lower roller ), then put in the steel.
(2) Start the left and right oil cylinders and add pressure to make upper roller press the steel which drives lower roller to bend steel.
(3) Add pressure gradually and drive rollers to rotate again and again. The bend is done.
8.1.3. Unload material
(1) Move upper roller to the location of central high limit, others don’t move, at this time, the upper roller is in balance.
(2) Overturn frame turns over to unload material.
(3) Overturn frame resets.
8.2.When roll circular arc work pieces, normally we first bend the end part.
8.2.1.Shown as diagram below, upper roller moves to one side and be adjusted to correspond height. Firstly, bend the end part.
8.2.2.Rotate work rollers, take central parts’ bending.
8.2.3.Work rollers reverse.
8.2.4.Upper roller goes up and moves to the other side.
8.2.5.Upper roller drops to correspond height which drives work rollers to bend surplus part of central area.
8.2.6.At last, bend end part of the other side.
End part bend
Symmetry bend
注: 建议图片大小150px*50px 
