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This equipment is a upper roller universal three roll bending machine, which is used to bend metal plates of a certain thickness into cylindrical, arc-shaped or certain taper parts at room temperature.
Its working principle is rotational bending deformation. Since the upper roller can move up and down as well as horizontally, there is no need for additional equipment such as a press. It can load materials at one time and can complete the pre-bending and forming bending functions of both ends of the plate without turning around, as well as the correction of the formed workpiece.
With the help of auxiliary devices, the ends of the sheet can be aligned with fewer straight edges remaining. Hot rolling can be carried out after adding heat insulation device. The upper roller universal 3 roll bending machine is an essential equipment for the machinery and equipment manufacturing industries such as petroleum, chemical industry, cement, shipbuilding, boiler, aviation, water conservancy, power transmission and transformation towers, etc.
① Indoor workshop.
② Ambient temperature 0～40℃, relative humidity ≯90%.
③ Power supply: 3～380V±10%, 50Hz±5.
④ Altitude: <2000m.
The lifting and lowering of the upper roller and head-turning of this equipment are all performed by hydraulic cylinders. All operations adopt CNC electrical centralized control. Easy to operate. The digital display is eye-catching and intuitive.
The upper roller lifting displacement, horizontal displacement and rolling parameters are all displayed digitally on the screen. After the plate thickness, rolling diameter, and material properties are input, the appropriate work roll position is automatically calculated and displayed on the touch screen for user reference. It also has "relative displacement" synchronization and "absolute displacement" synchronization conversion functions. Synchronization accuracy <±0.20 mm.
The upper roller also has a roller position setting function. Easy and flexible operation. At the same time, there is also a status display of PLC input and output. Makes maintenance more convenient.
When the end is pre-bent, the length of the straight edge can be freely controlled by changing the horizontal movement of the upper roller. The upper roller directly applies pressure to control the shape of the straight edge and achieve high-precision end preparation.
By adjusting the rollers, ideal products with high roundness and straightness can be rolled out in a wide range from thin plates to thick plates.
The upper roller universal 3-roller plate rolling machine has dual functions of pre-bending and rolling. Its structure mainly consists of an integral base, a tipping side frame, a fixed side frame, a work roll, a support roll device, a main transmission device, an upper roll moving device, a tipping device, a hydraulic pump station, an electronic control system and other components.
The whole bending roll machine is compact in structure, reliable in use and easy to maintain. Both the up and down movement of the upper roller and the horizontal movement of the upper roller are equipped with digital display devices. Therefore, it is easy to operate and accurate in control. The turning and resetting of the upper roller head are performed by the oil cylinder. The balance of the upper roller is completed by the unloading device, making unloading more convenient.
The two lower rollers of this rolling machine are driving rollers with fixed positions. After the main motor is decelerated by the main reducer, it is transmitted through the output shaft gear to the gears located at both ends of the lower roller to rotate the lower roller. The extended end of the input shaft of the reducer is equipped with a braking device. When the sheet material is clamped by the upper and lower rollers, friction is generated between the sheet material and the work roller, causing the sheet material to move. The three tangent points in contact between the three rollers and the metal plate form a radian to bend the flat plate. By adjusting the reduction amount of the upper roller, the curvature radius of the required arc or cylindrical workpiece can be achieved.
The upper roller of this three-roller plate bending machine is a driven roller, which relies on the friction between the work roller surface and the steel plate to rotate. Its up and down movement is driven by hydraulic cylinders at the top of both ends. The horizontal movement of the upper roller back and forth is driven by the brake motor through a pair of V-shaped pulleys to the input shaft of the auxiliary reducer, and then from the output shafts on both sides of the reducer through the coupling to the worm gear pair in the bearing seat. Through the rotation of the nut in the worm gear, the screw rod and the horizontal moving shaft connected to it are moved horizontally forward or backward, thereby driving the fixed side and tilting side frames together with the upper roller to move forward or backward horizontally.
There is an overturning cylinder at one end of the frame on the overturning side of the machine. When the rolling work is completed, the upper roller moves to the middle position and rises to a predetermined height, and the overturning cylinder moves to overturn the overturning side frame. After unloading the workpiece, the overturning cylinder moves again to restore the overturned side frame. At this point, a working cycle ends.
The overall base is made of steel and steel plates that are integrally welded and processed to relieve stress. It is wide and tall in the middle, with good strength and rigidity. It is easy to install and use, especially suitable for production requirements with high mobility. Lower requirements for foundation. Easy to relocate.
Due to the use of support rollers and a particularly stiff frame, the lower roller has very good stiffness. No adjustments are required to compensate for lack of lower roller stiffness. Convenient operation for workers. At the same time, the frame, reducer, motor, etc. are installed on it to form a whole.
The work roll is an important part of the plate rolling machine and is a refined forging. The lower roller and support roller adopt self-lubricating sliding bearings at both ends, which have the characteristics of large bearing capacity and easy maintenance.
The journals at both ends of the upper roll adopt new extra-wide large-scale double-row spherical roller series rolling mill rolling bearings. The bearing adopts international advanced technology and is developed in accordance with international advanced standards. Long service life and saving power consumption. Improve main transmission efficiency and reduce main transmission power. Due to the use of spherical roller bearings, the tilt of the upper roller is facilitated.
The rack is divided into a tilting side rack and a fixed side rack, one piece each. They are all made of steel plate welded structures and are tempered and finished.
The upper parts of the overturning side frame and the fixed side frame are equipped with upper roller pressing cylinders. The piston rod of the oil cylinder is connected with the bearing seats at both ends of the upper roller. The upper roller rises and falls together with the oil cylinder. The structure of the top-mounted oil cylinder is based on many years of practice. It absorbs the advantages of several Japanese, German, and domestic models and combines them with process requirements.
The two oil cylinders of the upper roller both work with rodless chambers to maintain the consistency of the system, that is, consistent working pressure, consistent compatibility, and a large effective area of the oil cylinder. There is only one dynamic seal. The lifting speed is suitable for the plate rolling process requirements and facilitates the control of the synchronization of the two cylinders. Easy maintenance and greatly enhanced maintainability.
The support roller is used to support the middle part of the lower roller to improve the rigidity of the lower roller and thereby improve the forming accuracy of the workpiece.
The main reducer adopts ZSY hard tooth surface cylindrical gear reducer and is installed on the overall base together with the pad. The auxiliary reducer adopts CWU arc tooth cylindrical worm reducer.
The unloading device is installed on one side of the reducer to balance the upper roller when unloading.
The overturning device is installed on one side of the overturned frame and is used to turn over and restore the overturned frame, which is performed by an oil cylinder.
Cast steel ingot (chemical composition analysis) - surface inspection - forging blank - post-forging annealing - flaw detection - rough machining (mechanical property experiment) - heat treatment (quenching and tempering) - semi-finishing - finishing - Roller surface heat treatment
Forging blank - surface inspection - rough machining - flaw detection - heat treatment (quenching and tempering) - semi-finishing - finishing - heat treatment (tooth surface quenching, etc.)
Plate entering the factory (chemical composition, mechanical performance inspection) - plate pretreatment - blanking - welding - weld inspection - annealing treatment - rough machining - vibration aging - finishing
The upper roller universal three roll bending machine adopts an independent hydraulic pump station, which is composed of an oil pump motor, a hydraulic valve group, and pipeline auxiliary parts. An oil pump motor drives the pump to output pressure oil. To ensure that the oil is clean, an oil filter is provided at the oil port of the oil pump. The pressure oil from the oil pump first enters the pressure regulating system to adjust the pressure, and then passes through the channel block and leads to the oil cylinder through the three-position four-way reversing valve.
The hydraulic pump station system is manufactured in strict accordance with international standards. Well laid out. Fully consider high efficiency, energy saving, waste reduction, and heat source reduction. The system is independent, and professional sealants are used at appropriate connection points to prevent leakage. Easy to repair and maintain.
Among them, hydraulic pumps and hydraulic valves are all from famous brand series. The cylinder is an ancillary product customized and produced by a professional hydraulic cylinder factory. The maximum working pressure of the system is 20Mpa. The pipeline layout is simple and there is less leakage. Easy maintenance and debugging.
The upper roller lifting and lowering synchronization system is controlled by PLC. Through the detection and feedback of hydraulic valves (electromagnetic reversing valve, throttle valve, hydraulic control check valve) and displacement sensor, automatic adjustment is performed, and the synchronization accuracy reaches ±0.20mm.
The electrical control system consists of an electrical control cabinet, an operating console, and a handheld control box. The control electrical appliances of this upper roller universal three roll bending machine (including PLC) are installed in the power distribution cabinet. It adopts touch screen display and operation, which is easy to operate.