W12-50x3000 Hydraulic four roller plate rolling machine

1. Summarize

This machine is a four roll plate bending machine, which is used to pre bend and roll the cylinder in the pressure vessel industry. It also has the functions of round and rough leveling.

The upper roll is the main drive, and the lower roll and side roll are driven to rotate by the friction between the steel plate and the roller to provide torque for the winding circle.

The upper roll is hydraulically driven by the active roller, while the lifting of the lower roll, the rollers on both sides, the head frame and the backup roll are driven by hydraulic pressure.

The synchronous accuracy is ≤± 0.15mm.

The end of the plate is clamped by the lower roll, and the side roll is inclined to rise to realize the plate end pre bending.

According to the arrangement of the adjustment positions of the rollers on both sides, symmetrical or asymmetric bending can be carried out. Therefore, this machine can roll into an ideal arc with very small theoretical residual straight edge at one time. Compared with the symmetrical three roll bending machine, there is no need to pre bend the plate end with a press.

The machine is equipped with centralized grease lubrication system.

The control system adopts the intelligent high-speed PLC to control the position of lower roll, two side roll, inverted head frame and back-up roll.

The encoder is used for the displacement sensor of the lower roll and the two sides roll, and the sensor action mechanism is designed reasonably to ensure the service life and precise monitoring.

All bearing pairs are required to adopt the most advanced technology and the leading products of the most famous manufacturers.

The hydraulic cylinder has high manufacturing precision, good sealing, reducing pressure relief and leakage; the sealing device is imported.

2. Main technical parameters

3. The structure of the machine

The equipment is composed of body, upper roller device, main transmission device, lower roller device, side roll device, balance device, overturning device, hydraulic system, electrical system, digital display system and lubrication system.

3-1. Body

The machine body is composed of base, fixed side frame and overturned side frame, and each part adopts steel plate welding structure.

The frames on both sides are fixed on the base by bolts, and the frames on both sides are connected together by connecting beams, so that the rigidity of the whole machine is good.

The two side frames are provided with motion guide rails for the lower and side rollers, the upper roller bearing seat is provided in the fixed side frame, which is a half closed frame structure, and the support device of the overturning frame is set in the overturning side frame. The force in the process of plate rolling is borne by the frames on both sides. The base not only supports the weight of the machine and ensures the accuracy of the equipment, but also balances the torque between the main drive and the frame, and connects the whole machine into one. In today's traditional large-scale four roller plate bending machine body and the main drive installation base is separate.

3-2. Upper roll device

The upper roller is driven by the main transmission device for rotary motion, and its two ends are supported by SP-1 sliding bearing. The transmission end is connected with the main transmission device through flat key and split gear to transfer torque. The overturning end is equipped with protective steel sleeve.

High quality alloy steel 42CrMo for upper roll, Quenched and tempered hb260-300.

3-3. Main drive

The torque is transmitted to the upper roller by the hydraulic motor

3-4. Lower roller device

The lower roller is supported on the self-aligning bearing, and the bearing seat is installed in the guide rail of the frame on both sides, and its lower end is connected with the piston of the oil cylinder. Under the action of hydraulic pressure, the bearing seat can rise and fall along the guide rail, and the thrust of piston rod can be adjusted arbitrarily by the pressure control valve of hydraulic system according to the demand of clamping steel plate force of upper and lower rollers.

3-5. Side roll device

The side roller is supported on the arc-shaped bearing seat, which is installed in the guide rail of the frame on both sides, and its lower end is connected with the piston of the oil cylinder. Under the action of hydraulic pressure, the bearing seat can rise and fall along the guide rail, and the thrust of piston rod can be adjusted arbitrarily by the pressure control valve of hydraulic system according to the demand of steel plate force. The side roll is also made of high-quality alloy steel, which is quenched and tempered hb260-300.

3-6. Balancing device

The balance device adopts the tension screw climbing mechanism. When the overturning frame breaks off the upper roller bearing and overturns, the upper roll at the end sags due to the gravity. In order to make the upper roller in the horizontal position, a balance device is set on the tail rod at the outer end of the fixed side and fixed on the base with bolts.

3-7. Tipping device

The overturning device drives the overturning frame to overturn and separate the upper roller bearing through the oil cylinder and hinge, so as to take out the products.

3-8. Lubrication system

The main reducer and side roll transmission reducer are lubricated by oil pool splash and naturally cooled. When the ambient temperature is - 10 ~ 0 ℃, N46 and N68 are used, N68, N100, N150 and N220 are used at 0 ~ 40 ℃. Other lubrication points are lubricated by manual oil gun. The working medium is calendering grease zgn40-1 (for winter) and zgn40-2 (for summer). The working system is to refuel 1-2 times per shift.

4. Hydraulic system

4-1. General overview

The hydraulic system is composed of gear pump, valve group, fluid connector and hydraulic auxiliary parts.

The hydraulic valve adopts Superposition valve series, with simple pipeline layout and convenient maintenance and debugging.

The system consists of three circuits, overpressure protection and pressure regulation circuit, synchronous 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.

The synchronous circuit synchronizes the ascending and descending coarse steps of the upper roller through the shunt throttle valve. The throttle valve is adjusted up and down to detect the displacement sensor. The positioning accuracy of the upper roll synchronization is ± 0.15mm.

The speed loop controls the overturning and resetting of the machine on the overturning side, and regulates the throttling speed of the circuit through the throttle valve.

4-2. Various protections

The up and down of the upper roller are respectively provided with relief valve for limit protection.

5. Electrical control system

Electrical parameters

Total power supply 50-60Hz 380V (220-690v customized)

Control power supply ~ 220VAC

PLC S7-200 smart series

Color display smart 700ie V3

The electrical control system of the machine tool is based on PLC, equipped with electrical control and hydraulic control to realize the action of the machine tool. The main operation keys are mainly on the operating platform. The synchronous digital control of the left and right side rollers and the lower roller must be operated and controlled under the operating state of the operating platform. The moving figures of each movement are displayed through the touch screen interface, which is convenient for intuitive operation. As the left and right side rolls and the lower roller work, the overturning frame work is powered by hydraulic source. Please start the oil pump motor before action.

PLC programmable controller

The PLC of the machine tool is S7-200 SMAT series multifunctional controller. The controller is composed of power supply part, CPU part, input part and output part. The frame part is used to place CPU, input and output parts, and provide all kinds of power supply required by PLC. The CPU part is the "brain" of PLC. It reads the state of input module, judges according to the stored user logic, and then controls the output module to drive the control object. Input part -- this part converts the state of external equipment (button, touch screen, displacement sensor, input and output signal of digital display instrument, etc.) into the signal that can be received by CPU module, and send it to the memory of CPU. When the external equipment is connected, the point will be lighted; output part -- this part drives the control object (relay, driving circuit board, contactor, electricity) according to the control command of CPU Magnetic valve, indicator light, etc.).

touch screen

The NC system takes PLC as the core, and is equipped with smart700ie V3 color display. It can display the current displacement value of each movement of the bending machine in the running state, and preset the displacement value of each roller. It forms a reliable and strong performance control system with PLC.

6.Rolling process of four roll rolling machine

A = pre bending roll (left side roll) B = roll (right side roll)

C = lower roll D = upper roll

Step 1: the steel plate touches the roll B (at this time, the position of the four working rolls is the initial position of NC automatic control).

Step 2: lift the lower roll C, clamp the steel plate and the upper roll D, reverse the upper roll D and the lower roll C at the same time, and exit the steel plate. When the front edge of the steel plate is in the tangent position of the upper roll D and the lower roll C, the rotation of the two rolls stops. At this time, the front edge of the steel plate is at the position of "0", and the subsequent one cut rolling length will take this as the base point.

Step 3: the roll B is lowered to the horizontal position, and the pre bending roll a is lifted to a predetermined position above the syncline. The pre bending roll a bends the steel plate and starts the pre bending.

Step 4: the upper roll D and the lower roll C rotate at the same time, roll the steel plate forward, and pre bend the plate.

Step 5: the front end of the steel plate has reached the upper part of the roll, the pre bending roll a is lowered, and the pre bending is completed.

Step 6: the plate rolling roller B rises to the predetermined position to roll the steel plate.

Step 7: if the steel plate is thin and the diameter of the workpiece is large, it is necessary to support the workpiece on the side to prevent its deformation.

Step 8: when the workpiece reaches the top, in order to prevent the workpiece from collapsing downward and deforming, it is necessary to support the workpiece in the center.

Step 9: when the end of the workpiece leaves the pre bending roller a, it is necessary to raise the plate rolling roller B a little higher, carry out the post pre bending, and finally the whole workpiece is rolled.

7. Main configuration

8. Accessories

• One book of operation Manual, Certificate of quality, Packing list.
• One set of sealing and foundation boot, one piece of oil gun.