Plate Rolling Machine Manual

We are a professional manufacturer of plate rolling machines with over 10 years of industry experience. Today, we would like to introduce the components of plate rolling machine to you:

Rolling machine as the core equipment for plastic processing of sheet metal, its structure system consists of four functional modules: bearing system, forming system, power transmission system and control system. Each system through the precision cooperation to realize the continuous bending and forming of the plate, this paper will analyze its core components from the mechanical engineering point of view of the construction principle.

1, Structural load-bearing system: Frame assembly

The rack system adopts a closed frame structure, which consists of three major cast steel components, namely, base, columns and beams, connected by pre-stressed bolts to form a stable load-bearing system. The column adopts double-column symmetrical layout, with finite element topology optimization design, the section moment of inertia reaches 3.8×10^6 mm^4, which can withstand a maximum working load of 8000kN. The beams are equipped with hydraulic preloading device, which monitors the structural stress distribution in real time through load sensors to ensure that the flatness error under the working condition is ≤0.05mm/m. The connecting parts are equipped with high-strength bolts with adjustable preloading force (grade 10.9), which are combined with self-lubricating joint bearings to effectively eliminate the structural gap under alternating loads.

2, Plastic forming system: Roll system components

The roll system consists of work roll, support roll and shaping mechanism with three-roll asymmetric layout. The main work roll is forged by 42CrMo alloy steel, the surface hardness is HRC58-62 after deep nitriding treatment, and the cylindricity error of the roll surface is controlled within 0.01mm. The lower roller group is equipped with double row tapered roller bearing support, axial positioning accuracy of ±0.02mm.The upper roller hydraulic cylinder is equipped with displacement closed-loop control system, the maximum stroke of 400mm, position repeatability of ±0.03mm.The array of support rollers is arranged according to the principle of equal curvature distribution, and the spacing is optimized by the elasticity-plasticity deformation simulation, which can effectively inhibit the plate bending and deformation.

3, Power Transmission System: Drive Assembly

The main drive system adopts AC servo motor (power 55kW) + planetary reducer (speed ratio 1:128) transmission program, the output torque reaches 125kN-m. The gearbox adopts herringbone teeth - helical teeth composite transmission structure, tooth contact stress ≤ 1500MPa, transmission efficiency ≥ 96%. The hydraulic system is equipped with constant pressure variable piston pump (rated pressure 31.5MPa), with proportional servo valve to realize the dynamic adjustment of roll gap, the system response time is ≤80ms. the safety circuit is equipped with mechanical overload protection device, which automatically cuts off the power output when the working pressure exceeds the limit by 15%.

4, Intelligent Control System: Operation Unit

The control system architecture includes PLC master station, distributed I/O modules and industrial-grade human-machine interface. The core control algorithm integrates real-time closed-loop PID regulation, material springback compensation model and self-learning function of process parameters. Displacement sensor (accuracy 0.001mm) and pressure transmitter (accuracy 0.5% FS) form a multi-parameter detection network, with a data sampling period of 2 ms. The operation terminal has a built-in material characteristics database, supports JIS/GB/ISO multi-standard parameter matching, and can store 2000 groups of process formulas. The safety protection system is equipped with light curtain protection (response time 15ms) and emergency stop redundant circuit (SIL3 level).

System synergy principle

When the machine is running, the control system automatically calculates the initial position of the roll seam according to the input sheet parameters (thickness, yield strength). The main drive system drives the work roll to rotate (linear speed 0.5-6m/min stepless adjustable), and the hydraulic cylinder applies molding pressure according to the preset curve. The plate undergoes three stages of elastic deformation (radius of curvature R≥500t), elastic-plastic deformation (50t≤R＜500t), and pure plastic deformation (R＜50t, t is the thickness of the plate) between the roll systems. During the forming process, the laser range finder provides real-time feedback of curvature data, and the control system dynamically corrects the roll gap parameters, so that the final forming accuracy reaches GB/T1804-m level.

The structural system realizes functional decoupling through modular design, and each sub-system can be maintained independently and work together, which fully balances the engineering contradiction between equipment rigidity, forming accuracy and operation convenience, and embodies the typical characteristics of modern mechanical equipment system integration.

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