Four-roller CNC rolling machine
1 Overturn cylinder 2 Overturn frame 3 Left frame 4 Upper roller 5 Side roller 6 Lower roller 7 Right frame 8 Balance device 9 Upper roller drive device 10 Lower roller drive device (optional) 11 Side roller cylinder 12 Lower roller cylinder 13 Base 14 Side bracket (optional) 15 Upper bracket 16 Electric feeding platform (optional) 17 Hydraulic system 18 Electronic control system
1. Overview of the subject
The hydraulic CNC five-axis Plate Rolling Machine is one of our company's flagship products. It is specially designed and manufactured for rolling cylindrical workpieces made of stainless steel, galvanized sheets, cold plates and other metal materials. And has a number of national related patents. Long-term production and processing has enabled our company to accumulate rich technical experience, making our equipment at a relatively advanced level. The machine tools produced by our company have stable performance and easy operation. The CNC five-axis Plate Rolling Machine produced by our company has the advantages of good rolling roundness, no need for separate pre-bending, small rolling straight edges, and one-click start of rolling forming.
1-1. Main body overview
This machine is fully hydraulically driven, digitally controlled, with advanced structure, superior performance and high efficiency. Features of our CNC plate bending machine: 1. The side rollers move linearly to increase work stability. 2. Both sides of the pressure roller are controlled by absolute encoders for synchronization.
The following users are suitable for using this CNC Plate Rolling Machine:
1. First time users of Plate Rolling Machine, because this is an easy-to-operate plate rolling machine
2. Operators lack inspection and require higher productivity
3. Require higher precision and improve quality
4. Hope to reduce operators and reduce labor costs
Features of this machine:
1. Full hydraulic drive, high efficiency and energy saving (the driving power is equivalent to 60% of the traditional one). Compared with the traditional three-roller plate rolling machine, the rolling operation is safer and more reliable;
2. Permanent lubrication technology (no need to refuel during the bearing life);
3. The clamping pressure is adjustable (there is no slipping, and the productivity is 50%-80% higher than that of a three-roller plate rolling machine). The clamping force of the plate between the upper and lower rollers can be adjusted differently through the pressure regulating valve of the hydraulic station. The corresponding required pressure when rolling the thickness and width of the plate;
4. It can roll a cylinder with a minimum diameter of 1.3 times the diameter of the upper roller. When the end of the rolled plate is pre-bent, the length of the straight edge is smaller than that of other types of plate rolling machines.
2. Working principle (see picture)
3. Main technical parameters
Model SD-1500-5
Upper roller diameter Φ 170 ㎜
Lower roller diameter Φ 160 ㎜
Side roller diameter Φ 140 ㎜
Maximum rolled plate thickness 6mm
Maximum pre-bent plate thickness 4.8mm
The maximum width of the rolled plate is 1500mm
Work roll drive type Upper roll hydraulic motor drive
Yield limit of plate ≤245Mpa
Rolling speed about 6m/min
Pre-bent remaining straight edge ≤1.5 plate thickness
Minimum drum diameter: about Φ250mm
Total equipment power 5.5KW
4. Main structure
4-1. Main structure
The main structure of the equipment is composed of an upper roller device, a lower roller device, a side roller device, a main transmission device, a tipping device, left and right side frames and a chassis.
The upper roller is the driving roller, which is powered by a hydraulic motor. The upper roller can rotate forward and reverse, and the rollers on both sides are driven rollers. The side rollers move linearly up and down along the frame guide rails. The rotation of the side rollers is driven by the friction between the steel plate and each roller. The raising and lowering of the lower roller and side roller, and the overturning and resetting of the upper roller overturning frame are all implemented by hydraulic cylinders to clamp the rolled sheet and achieve asymmetric bending.
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The frame is a steel plate welded structure, and is annealed after welding to eliminate stress. The lifting and lowering of the rollers on both sides is arranged inside the fixed and overturned frame, the lifting and lowering of the lower roller is arranged in the middle of the machine tool, the hydraulic transmission device is directly coupled with the work roll, and the entire hydraulic pump station is placed at the rear or middle of the chassis. All operations are performed on the control panel on the side of the machine.
The position of the upper roller is fixed, and it is held down by a balance device installed at the rear of the machine tool. The oil cylinder performs the overturning and resetting of the upper roller overturning frame.
4-2. Use new rolling bearings for rolling mills
Our company has also adopted a number of energy-saving measures on the plate rolling machines. New bearings (rolling bearings) used in rolling mills are used in the journals of the upper, lower and side rollers, which greatly reduces the power of the main motor and greatly improves the non-slip condition. During symmetrical rolling, the clamping force of the lower roller can be greatly reduced. It not only saves energy but also can roll thinner steel plates and smaller diameters.
The work roll journal of this machine adopts new rolling bearings. The new rolling bearings adopt advanced technology and are developed by the manufacturer according to advanced standards. The bearings have long service life and save energy. In addition, the adoption of the lower roller drive technology removes the distribution box, improves the main transmission efficiency, reduces the main transmission power, has a long service life, small friction resistance, greatly improves the non-slip conditions, and can roll thinner steel plates. The lower and side rollers use extra wide series of large double-row self-aligning roller bearings, which facilitates tilting when rolling the cone without causing mechanical interference (the cone rolling machine needs to be optional).
4-3. Transmission system
4-3-1. Main drive
The upper roller is a driving roller, which is directly coupled and driven by a hydraulic transmission device (including planetary reducer, brake, hydraulic motor, balance valve, overload valve, etc.). The material is 42CrMo. It undergoes rough machining, quenching and tempering heat treatment (HB280-300), and fine machining. Become.
(Pictures are for reference only, the actual design shall prevail)
4-3-2. Auxiliary transmission
The lower roller is lifted and lowered by two oil cylinders to push the lower roller up and down. The displacement of the two cylinders is detected by a displacement sensor, and the synchronization accuracy is high. However, when the lower roller is mechanically driven to rise and fall, the mechanical gap is large, the positioning is inaccurate, the work efficiency is low, the energy consumption is large, and the pressing force is difficult to control and overload occurs. This structure can not only meet its synchronization, but also the pressure can be controlled, and there will be no overload phenomenon.
The rollers on both sides are driven rollers, which are driven by friction. Both the fixed and tilting frames are equipped with side roller bearing slides.
The roller lifting cylinder is connected with the side roller bearing seat. Each side roller is driven up and down by two oil cylinders. Each side roller oil cylinder is detected by an angular displacement sensor, so that the lifting and lowering displacement of the side roller is displayed on the screen, which is eye-catching and intuitive, and ensures that both ends of the side roller are ensured. Synchronize.
5. Hydraulic system
5-1. Main body overview
The hydraulic system consists of hydraulic pumps, valve groups, auxiliary pipeline parts, etc. The hydraulic valve pipeline layout is simple, the leakage possibility is minimal, and maintenance and debugging are easy. Each input and output port of the hydraulic system is equipped with corresponding detection points to facilitate maintenance and fault inspection. In addition, the hydraulic station is placed on the base to reduce the space, making the foundation simple and easy to transport.
1. The system consists of three types of circuits: overpressure protection and pressure regulation circuit, synchronization circuit, and speed circuit. The pressure regulation circuit regulates the system operating pressure through the main relief valve.
2. The lower roller and side roller are respectively equipped with relief valves for pressure limit protection when rising and falling.
3. In order to ensure the synchronization accuracy of the oil cylinder, a high-precision displacement sensor is installed on the right frame and tipping frame. Through pressure sensing
The microcomputer control system detects and adjusts the movement of the main cylinder piston to meet the synchronization accuracy requirements at both ends of the work roll.
5-2. Technical features
1. Adopt pre-pressure relief technology to effectively avoid hydraulic shock and extend the life of pipelines and seals.
2. Hydraulic components are made of imported high-quality products to ensure the stability of the hydraulic system.
3. Each input and output port of the hydraulic system is equipped with corresponding detection points to facilitate maintenance and fault inspection. The oil pump is bottom-mounted.
Positive pressure oil suction. In addition, the hydraulic station is independent of the machine base, making repair and maintenance convenient; and it is far away from heat sources.
4. The system is manufactured in strict accordance with international and industry standards. The pipe bend radius is reasonable and not less than 90°. The transition is smooth and the vibration-absorbing pipe clamps are reasonably arranged to effectively avoid impact and vibration.
5. The system design fully considers high efficiency and energy saving, reducing power waste and reducing heat sources.
6. Equipped with high-precision oil suction and return filters to ensure the cleanliness of the system oil.
7. Provide common fault phenomena and troubleshooting methods of the hydraulic system of the plate bending machine.
8. In order to ensure the manufacturing quality of the hydraulic system, the system is manufactured in accordance with the professional hydraulic manufacturer and the national GB3766-83 "Hydraulic System
"General Technical Conditions".
9. The fuel tank has been shot blasted, pickled and surface cleaned, and the four walls are coated with oil-resistant varnish to ensure the tank is clean. There is an air filter at the refueling point of the fuel tank to ensure oil filtration and ventilation. In addition, a fine filter must be installed at the end of the oil suction pipe and the oil supply pipeline.
The normal operating temperature range of the hydraulic system is 15℃~65℃. When the temperature is greater than 65℃, the temperature of the oil can be controlled by the cooler to make it suitable for the system working requirements.
5-3. Main technical indicators of the system
The system operating voltage is 380v, 50Hz
Ambient temperature is - 15~40℃
Relative humidity is ≤85%
6. Electronic control system
The process software is run through a PLC programmable control system. The rolling process has a high degree of automation, high product precision, low equipment failure rate and high work efficiency. Features of this software: The rolled cylinder can be rolled into a round shape with one click without repeated trials. The obtained data can be used to roll standard cylinders on a large scale.
6-1. General overview
The equipment electronic control system consists of an operating table, a console, and a handheld button box. Power supply three-phase 380V/50Hz.
The control circuit adopts PLC programmable control system. The rolling process has a high degree of automation, few relays, reliable action and long life.
The control cabinet is equipped with all control buttons and indicator lights for completing the product rolling process to monitor and control the rolling working status of the entire machine.
The electrical system controls the hydraulic system to automatically compensate, and the synchronization accuracy of the side roller and the lower roller is maintained within 0.4mm. Digital display, the movement displacement of each mechanism is synchronized with the numbers.
The electrical system has an independent operating console and is movable.
6-2. Various protections
The motor has a corresponding circuit breaker for overcurrent short circuit protection;
The motor has a corresponding thermal relay for load protection;
The overturning and resetting of the overturning cylinder are respectively equipped with upper and lower limit switch limit protection;
The main power circuit breaker has a separation release, and there are "emergency stop" buttons on the console and the tipping support side to remotely cut off the main power supply. 6-3. Fault indication
When the PLC fails, the fault indicator light prompts.
6-4. Function overview
Adopt human-machine conversational electrical interactive control system. According to the basic functions of the arc downward-adjustable plate rolling machine required by the user, the tasks are decomposed, and combined with the development form of the machine, the functions of its electrical control system are as follows: 6-4- 1. It has both a portable and operating console mode of operation
Since the operator needs to adjust the position of the machine's work roller at any time during the plate rolling process, a mobile control cabinet is equipped for ease of operation.
6-4-2, with automatic positioning function
During the batch rolling process of the plate rolling machine, we can record the position of the previous work roll, enter the position to go to, and the machine will automatically locate the previous position, saving the time spent adjusting the position of the work roll before each roll. , thereby improving processing efficiency.
6-4-3. Parameters can be modified online
The online modification of parameters can meet the different requirements of each user, making the machine have certain scalability, with functions such as data exchange and control command transmission. The control command transmission between controllers and the control system have communication functions. For example: when the machine encoder is damaged, the maintenance personnel only need to replace it with a new displacement encoder and then set the pulse equivalent appropriately. There is no need to select the same type of encoder, which facilitates maintenance. 6-4-4. Conduct real-time monitoring of the entire system. The power of the plate rolling machine is generally very large, and safety issues are particularly important during its operation. Through the preparation of PLC programs, some malfunctions are limited and timely issued. alarm signal, thereby reducing the occurrence of accidents.
6-4-5, realize synchronous lifting and lowering of work, independent lifting, and simultaneous lifting and lowering in tilted state.
When the lower roller is raised and lowered synchronously, the overturning side and the fixed side of the side roller are required to rise or fall at the same time. Since the lower roller is raised and lowered by two hydraulic cylinders, it is necessary to control the synchronization of the two hydraulic cylinders. In fact, we can achieve zero-error synchronization. It is impossible to achieve. We rely on the wire displacement sensor to continuously monitor the position of the fixed side and the tipping side lower roller, compare the difference with the given error, and then take corresponding actions to control the difference within a certain limit. within the range. The synchronization error given by the user must be appropriate. If it is too small, the solenoid valve will click frequently, which will reduce the life of the machine. At the same time, due to the limitation of the accuracy of the sensor, too small a synchronization error cannot be achieved; if the synchronization error is too large, the positioning accuracy will be reduced. It rises and falls at the same time in the tilted state, which is beneficial to the rolling of the cone.
6-4-6． Has braking system
Since the operating conditions of the plate rolling machine are characterized by frequent starting and braking with load, the main movement (rotary movement of the upper and lower rollers) is equipped with a braking system to reduce the moment of inertia and improve movement accuracy and smoothness. 6-4-7. The electrical system has complete protection links
In the design and operation of the electrical control system, considering the possibility of various faults and abnormal working conditions in the system, various protections need to be installed, such as overcurrent, overload, short circuit, loss of voltage, phase failure protection, etc.
7. Functional analysis
7. 1 Equipped with symmetrical three-roller bending machine function
The upper roller of this CNC plate bending machine is fixedly rotated, and the two side rollers rise and fall linearly around the fixed center. The two side rollers can be conveniently adjusted through the operating console to make the three work rollers form a "pin" shape, which forms a symmetrical three-roller plate bending machine and has the function of a symmetrical three-roller plate bending machine.
7.2 One-time loading without turning around to complete pre-bending and rounding of both ends of the sheet
The two side rollers of this plate bending machine can be raised and lowered linearly independently. During operation, the lower roller is raised to clamp the sheet material, and one of the two side rollers is at the lower part to provide support, forming an asymmetrical three-roller plate bending machine to achieve pre-bending of one end of the sheet material. The roll on one side where the pre-bent sheet is formed is lowered and the roller on the other side is raised, forming an asymmetrical three-roller at the other end of the pre-bent sheet. Therefore, the five-roller CNC plate bending machine is a combination of two asymmetrical three-roller plate bending machines. It has the function of pre-bending and rounding the two ends of the sheet without turning around at one time.
7.3 Wide rolling range
The two lower rollers of ordinary three-roller plate rolling machines are active rollers and the upper roller is passive roller. It is easy to slip when rolling thin plates and small diameter workpieces. The standard stipulates that the coil thickness cannot be less than 1/3 of the maximum coil thickness specified in the parameters; the minimum roll diameter is 1.5 times the diameter of the upper roller. The upper roller of the five-axis plate rolling machine is the main driving roller. It is allowed to roll sheets with a minimum thickness of 1/5 of the maximum coil thickness specified in the parameters, and the minimum roll diameter can reach 1.3 times the diameter of the upper roller. It can also be equipped with inner brackets and outer brackets to meet the needs of rolling thin plate workpieces with large diameters.
7.4 Automatic alignment during plate rolling
The plate side rollers are automatically aligned immediately and work like a hydraulic ruler. The structure diagram is as follows:
7.5 Plate feeding
The sheet is always clamped between the upper and lower rollers of the two rollers to ensure consistent and ideal positioning. The structure diagram is as follows:
(Pictures are for reference only, actual