W11s-25x3000 universal upper roller plate rolling machine With pre bending

W11s-25x3000 universal upper roller plate rolling machine With pre bending

W11S-25 × 3000 Universal Rolling Machine Diagram

1、 Main body overview

This machine belongs to the hydraulic three roll plate rolling machine, which is used to load various containers of carbon steel and low-alloy steel at room temperature without turning around, and complete the processes of pre bending, rounding, and straightening the plate ends.

The upper roller can move vertically or horizontally.

Pre bending is achieved by horizontally moving the upper roller to an asymmetric position relative to the lower roller.

When rolling, the two lower rollers are driven by an electric motor and a reducer.

Due to the unchanged elevation of the lower roller, it is convenient for feeding and operation.

Using industrial touch screens, the NTOUCH touch screen can work best with PLCs.

Provide detailed electrical schematics, strictly follow the drawings for electrical wiring, and ensure that the numbers on both ends of each wire are clear and complete. The wire terminal block should be labeled with the same wire number as the wire, and corresponding markings should be made on the electrical wiring diagram and schematic.

The electrical components used in the equipment are all high-quality products from well-known enterprises. Electrical protection devices (such as current relays, air switches, etc.) undergo strict testing before installation to ensure reliable operation.

The hydraulic components used in the equipment are Yuci Oil Research products.

The equipment runs smoothly, controls flexibly, has no jamming, oil leakage, and abnormal noise.

The paint surface is smooth and shiny, the paint mold thickness is uniform, and there are no defects such as flow marks or missed spraying.

The tipping frame adopts hydraulic tipping, which has a fast speed.

The vertical displacement of the upper roller is driven by hydraulic transmission, while the horizontal movement is driven by mechanical transmission with faster speed.

The equipment has high reliability and low failure rate.

2、 Main technical parameters

1. Apply pressure of 200 tons

2. Maximum board width 3000 mm

3. The maximum thickness of the rolled plate is 25 mm

4. Upper roller diameter Φ 410 mm

5. Lower roller diameter Φ 235 mm

6. Pre bending thickness 20 mm

7. Rolling speed is about 4.2 m/min

8. Number of roller groups: 1 group

9. Equipped with a power of 30KW

10. Hydraulic motor 11KW

11. Mobile motor: 3KW

12. Size 4800 * 2200 * 2500mm

13. Weight 17 tons

3、 Main structure

The main structure of the equipment consists of an upper roller device, a lower roller and horizontal moving device, a roller support device, a main transmission device, a tipping device, left and right side frames, a chassis, and a balancing device.

3-1. Upper roller device

The upper roller device consists of a main oil cylinder, an upper roller bearing seat, an upper roller, and double row self-aligning bearings.

The two main oil cylinders provide the required pressure for rolling the sheet metal, and the working pressure of the main oil cylinder is 19.5 MPa.

Double row self-aligning bearings use low-speed, heavy-duty self-aligning roller bearings.

The upper roller is in a drum shape, and during design, the load coefficient of the maximum applied pressure on the upper roller is 0.7 uniformly distributed load to pre compensate for the deformation and deflection of the upper roller under stress.

The upper roll is made of 45 # steel, quenched and tempered after rough machining, HB260~300, and roll surface HRC40-50.

(Upper roller device)

3-2. Lower roller device

The lower roller device consists of a lower roller, a lower roller bearing seat, a lower roller input gear, a lower roller sliding bearing, etc.

The lower roll sliding bearing is made of composite material, and the lower roll is made of 45 # steel. It is quenched and tempered after rough machining, HB245~250, and the roll surface is HRC40-50.

The horizontal moving device is powered by a horizontal moving motor, which drives the horizontal movement of the upper roller device through a worm gear box, worm gear, and screw mother mechanism, achieving asymmetric rolling of the sheet metal.

The main transmission of the lower roller provides power, which is transmitted through the output gear of the main transmission, the input gear of the lower roller, and the open transmission torque to the lower roller.

(Lower roller and horizontal moving device)

3-3. Roller device

The roller device consists of a roller, a worm gear mechanism, a wedge mechanism, etc.

The idler roller is a forged piece that has undergone quenching and tempering treatment, with a hardness of HB190~220. The surface hardness of the roller is lower than that of the lower roller.

There are four rollers in each group, and they are adjusted up and down according to the load size of the rolled sheet specifications.

(Roller device)

3-4. Main transmission device

The main transmission device consists of a main motor, a V-belt, a cylindrical gear reducer, an electro-hydraulic push rod brake, etc. The output gear drives two lower roller gears.

The main drive can rotate in both forward and reverse directions, providing winding torque for the sheet metal.

(Roller device)

3-4. Main transmission device

The main transmission device consists of a main motor, a V-belt, a cylindrical gear reducer, an electro-hydraulic push rod brake, etc. The output gear drives two lower roller gears.

The main drive can rotate in both forward and reverse directions, providing winding torque for the sheet metal.

(Main transmission device)

3-5. Overturning device

The tipping device consists of a slider, a tipping cylinder, etc.

Overturning the oil cylinder piston rod with chrome plating treatment.

The flipping device facilitates the removal of products along the axial direction of the roller.

(Overturning device)

3-6. Fixed, overturned side frame, chassis

The fixed and overturned side frames and chassis are welded steel plates, and stress is removed by vibration aging after welding.

The fixed and overturned side frame is used to accommodate two main oil cylinders.

The chassis adopts a frame structure, with a high anti torsion section coefficient, few anchor bolts, and easy installation and debugging.

4、 Hydraulic system

4-1. Overall Overview

The hydraulic system consists of plunger pumps, valve groups, fluid connectors, hydraulic accessories, etc.

The hydraulic valve adopts the Yuci Oil Research Stacked Valve series, with a simple pipeline layout and easy maintenance and debugging.

The system consists of three circuits: overpressure protection and pressure regulation circuit, synchronization circuit, and speed circuit.

The pressure regulating circuit adjusts 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 coarse steps of the upward and downward movement of the upper roller through a diversion throttle valve, and adjusts the throttle valve up and down; Encoder detection.

The speed circuit controls the flipping and resetting of the flipping side machine, and adjusts the throttling speed of the circuit through a throttle valve.

4-2. Various protections

The upward and downward movements of the upper roller are respectively protected by overflow valves for pressure limit protection.

5、 Electrical control system

5-1. Overall Overview

The equipment electrical control system consists of an operation console and a handheld button box. Power supply three-phase four wire system 380V/50Hz.

The control circuit adopts a PLC programmable controller system, with reliable relay action and long service life.

The control cabinet is equipped with all control buttons and indicator lights for completing the product rolling process, in order to monitor and control the rolling work status of the entire machine.

5-2. The touch screen screen can display fixed and horizontally movable positions, and can also set the downward and horizontal positions of the upper roller. Press the display area of the set position to pop up the numeric keypad. After entering the set amount according to the request, press "ENT". The horizontal movement setting is preceded by a "+" or "-" symbol and can be switched between buttons, representing the forward or backward movement of the upper roller. When the upper roller is in the center, it is set to "0".

In any screen, press the "System Run" button to display the position of the rotary encoder and set the position of the upper roller. The position of the upper roller can be synchronously controlled. According to the set displacement, press the "Upper Roller Run" button to synchronize the flipping side and fixed side to the desired position; After pressing the "Upper Roller Reset" button, flip over and fix the ruler to return to the zero position, and reset to the initial position (upper top). When the upper roller is at the top or pressing the sheet and in contact with the lower roller, horizontal movement is not allowed.

5-3. Various protections

Each motor has corresponding circuit breakers for overcurrent and short circuit protection;

Each motor has corresponding thermal relays for overload protection;

There are corresponding limit switches for the horizontal movement of the upper roller and the lifting of the support roller for limit protection;
The overturning and resetting of the overturning cylinder are respectively equipped with upper and lower limit switches for limit protection;
The main power circuit breaker has a shunt release, and there is an "emergency stop" button on the control panel and flip bracket side to remotely cut off the main power.
5-4. Various interlocks
After the overturning frame has been fully reset, actions such as lifting and lowering the upper roller, moving forward and backward, reversing the lower roller, and lifting and lowering the support roller can be carried out (detected by the "overturning frame reset" limit switch);
When the upper roller is in the upper position, the horizontal movement of the upper roller and the individual descent of the overturned side cannot be carried out (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 forward or backward, and the idler cannot be raised or lowered (the pressure relay is used for detection).
5-5. Fault indication
When the lower roller motor, horizontal movement motor, and idler motor are overloaded, the fault indicator light will prompt;
When the PLC malfunctions, the fault indicator light will prompt.
5-6. Distribution specifications
1. The construction power system adopts a three-phase four wire system, implementing a three-level control and two-level protection distribution method. The leakage current of the first level protection leakage protector should be determined according to the number of electrical equipment, but the rated leakage action time should be less than 0.1s.
2. When the construction site shares a system with external power lines, electrical equipment should be grounded or protected according to local requirements. It is not allowed for some equipment to be grounded or protected for neutral while others are grounded.
3. The protective neutral wire should be laid separately and not allowed to pass through any switches or fuses.
4. The protective neutral line should be grounded again at branches, endpoints, equipment concentration points, or every 50m in length, with a grounding resistance of less than 10 Ω.
5. The protective neutral wire of electrical equipment adopts insulated multi stranded copper wire with a cross-sectional area not greater than 1/2 of the phase line cross-sectional area and not less than 2.5mm.
6. The protective neutral wire of electrical equipment shall not be connected in series. The protective neutral wire shall be connected by reliable methods such as welding, crimping, and bolt connection, and winding and hooking are strictly prohibited.
7. Each electrical equipment should be equipped with an independent control switch and leakage protector (one switch, one protection, one machine), and it is strictly prohibited to use one switch for multiple purposes.
8. The use of knife switches is not allowed for control switches. If the air switch and leakage protector are matched with the electrical equipment, relatively stable, and have a starting control switch, the air switch can be omitted.
6、 Technical features of the upper roller universal plate rolling machine
6-1. Drum shaped upper roller, lower roller, and lower support roller are adjusted to achieve high-precision product straightness
The drum shaped upper roller is used, and the preset amount of the drum shaped upper roller is generally 70% of the uniformly distributed load of the roller; The lower roller with a smaller diameter is supported by adjustable rollers at the bottom. According to the load of the rolled product, adjusting the support roller at the lower part of the lower roller greatly improves the straightness of the product.
6-2. Rear bending and rolling, high-precision product roundness
The upper roller universal bending machine adopts rear bending (the direction of sheet feeding is opposite to the direction of upper roller movement), with the upper roller pressing down while the lower roller rotates, continuously bending. The end of the sheet is pre bent by direct pressure pre bending, avoiding the generation of front bending angles and controlling the length and shape of the remaining straight edges.
Generally, the three roll asymmetric type adopts front bending, pre bending the two ends of the sheet first, and then symmetrically rolling and forming, requiring skilled operators. The product has rear corners, and the shape of the remaining straight edges is difficult to control.
6-3. Reduce the amount of product misalignment
The universal rolling machine with upper rollers has taken the following measures to reduce the amount of product misalignment:
① The precision of the dimensions and positional tolerances of the two lower rollers and the center distance between the two lower rollers are key process controls;
② The synchronous electro-hydraulic combination of the upper roller adopts a feedback system for automatic leveling.
The stroke of the upper roller oil cylinder is detected by a rotary encoder, and the controller compares the high and low levels to the programmable controller, which controls the electromagnetic reversing valve electromagnets at both ends of the upper roller and continuously provides feedback comparison.
7、 Design, Manufacturing, Installation, and Acceptance Standards for Universal Rolling Machine with Upper Roller
JB/T1829-1997              General Technical Conditions for Forging Machinery
GB17120-1997              Safety Technical Conditions for Forging Machinery
JB/T8609-1997              Technical Conditions for Welding Parts of Forging Machinery
JB3623-84                  Measurement conditions for noise of forging machinery
JB/ZQ4000.5                General technical specifications for castings
JB/ZQ4000.9                General technical specifications for assembly
JB/ZQ4000.10               General Technical Conditions for Painting
GB3766-83                 General technical specifications for hydraulic systems
GB16754-1997              Design principles for mechanical safety emergency stop
GB/T5226.1-1996           Industrial machinery - Atmospheric equipment - Part 1: General technical specifications
8、 Main standard component configuration
8-1. Double row self-aligning bearing tile shop
8-2. Main Hydraulic Valve Yuci Oil Research
8-3. Gear Pump Hefei Hydraulic Parts Factory
8-4. Main motor Shanghai Ruijiate
8-5. Auxiliary motor Shanghai Ruijiate
8-6. PLC Programmable Logic Controller OMRON
8-7. Domestic sealing rings
8-8. Displacement sensor KOYO
8-9. Main reducer Shanghai reducer
9、 After sales service
The quality warranty period is one year, and detailed operating instructions are provided. Free accessories can be provided for foreign orders.With pre bending