operating manual & instructions of 3-roll plate rolling machine (1)
W11S-60×3200 3-Roll Plate Bending Machine is mainly used for bending forming of metal materials. It can roll around, arc, and conical workpieces within a certain range, and has a high-precision plate end pre-bending function.
Widely used in petroleum, chemical, boiler, shipbuilding, hydropower, metal structures, and machinery manufacturing industries.
W11S vs W12 plate rolling machine
When comparing the W11S and W12 plate rollers, it’s important to note that both machines are commonly used for plate rolling but differ in their design and capabilities. Here’s a comparison between the W11S and W12 plate rollers:
W11S Plate Roller
The W11S plate roller is a three-roll machine, also known as a three-roll asymmetrical plate rolling machine. It consists of three rolls, two lower rolls, and one upper roll. The W11S plate roller is primarily designed for medium to heavy-duty plate rolling applications. Here are some key features and characteristics of the W11S plate roller:
- Design: The W11S plate roller has an asymmetrical design, meaning that the two lower rolls are fixed in position, while the upper roll can be adjusted vertically to achieve different bending results.
- Rolling Capacity: The W11S plate roller is capable of rolling thicker plates and handling higher bending forces compared to some other plate rollers. It is suitable for rolling medium to heavy gauge plates.
- Bending Flexibility: The asymmetrical design of the W11S plate roller allows for different bending processes, such as pre-bending, rolling, and post-bending, depending on the requirements of the specific application.
- Ease of Operation: The W11S plate roller is relatively straightforward to operate, with intuitive controls for adjusting the position of the upper roll and controlling the rolling process.
W12 Plate Roller
The W12 plate roller is a four-roll machine, also known as a four-roll symmetrical plate rolling machine. It features four rolls, two lower rolls, and two upper rolls. The W12 plate roller is commonly used for various plate rolling applications and offers several advantages over the W11S plate roller. Here are some key features and characteristics of the W12 plate roller:
- Design: The W12 plate roller has a symmetrical design, with two upper rolls and two lower rolls arranged in a symmetrical configuration. This design provides improved balance and distribution of forces during the bending process.
- Rolling Capacity: The W12 plate roller has a wide range of rolling capacities, suitable for both light and heavy-duty plate rolling. It can handle various plate thicknesses and is capable of rolling thinner plates compared to the W11S plate roller.
- Bending Precision: The symmetrical design of the W12 plate roller ensures consistent and precise bending results. It offers superior control over the plate during the rolling process, resulting in higher accuracy and better-quality bends.
- Greater Bending Flexibility: The W12 plate roller allows for more complex bending operations due to its symmetrical configuration. It can perform operations like double pre-bending, pyramid rolling, and cone rolling more efficiently than the W11S plate roller.
Conclusion
Both the W11S and W12 plate rollers are reliable machines for plate rolling applications. The choice between the two depends on the specific requirements of the project, including the plate thickness, bending precision needed, and the complexity of the bending operations. While the W11S plate roller is suitable for medium to heavy-duty applications, the W12 plate roller offers greater bending flexibility and precision, making it ideal for a wider range of plate rolling tasks.
Technical data of w11s 3-Roll Plate Roller
| odel | Max thickness of rolling plate (mm) | Max biggest book plank widh (mm) | Prebngding plate max thickness (min) | Dia of upper roller (mm) | Dia of lower roller (mm) | Center to Center Distance of Two Lower Rollers (mm) | Motor Power (kw) | Hydraulic Motor Power (kw) |
| 6×1500 | 6 | 1500 | 4.5 | 175 | 125 | 160 | 3 | 2.2 |
| 6×2000 | 6 | 2000 | 4.5 | 205 | 125 | 160 | 4 | 2.2 |
| 6×2500 | 6 | 2500 | 4.5 | 235 | 135 | 180 | 4 | 2.2 |
| 6×3200 | 6 | 3200 | 4.5 | 245 | 145 | 200 | 7.5 | 4 |
| 8×2000 | 8 | 2000 | 6 | 235 | 135 | 180 | 5.5 | 2.2 |
| 8×2500 | 8 | 2500 | 6 | 245 | 145 | 200 | 7.5 | 4 |
| 12×2000 | 12 | 2000 | 9 | 255 | 150 | 245 | 7.5 | 4 |
| 12×2500 | 12 | 2500 | 9 | 300 | 165 | 270 | 11 | 5.5 |
| 12×3000 | 12 | 3000 | 9 | 320 | 180 | 300 | 15 | 5.5 |
| 16×2000 | 16 | 2000 | 12 | 300 | 165 | 270 | 11 | 5.5 |
| 16×2500 | 16 | 2500 | 12 | 320 | 180 | 300 | 15 | 5.5 |
| 16×3200 | 16 | 3200 | 12 | 380 | 200 | 330 | 22 | 7.5 |
| 20×2000 | 20 | 2000 | 16 | 320 | 180 | 300 | 15 | 5.5 |
| 20×2500 | 20 | 2500 | 16 | 380 | 200 | 330 | 22 | 7.5 |
| 25×2000 | 25 | 2000 | 20 | 380 | 200 | 330 | 22 | 7.5 |
| 25×2500 | 25 | 2500 | 20 | 410 | 235 | 380 | 30 | 11 |
| 30×2000 | 30 | 2000 | 25 | 410 | 235 | 380 | 30 | 11 |
| 30×2500 | 30 | 2500 | 25 | 460 | 260 | 420 | 37 | 15 |
| 30×3000 | 30 | 3000 | 25 | 480 | 260 | 420 | 37 | 15 |
| 30×3200 | 30 | 3200 | 25 | 510 | 275 | 460 | 45 | 15 |
| 30*4000 | 30 | 4000 | 25 | 590 | 290 | 500 | 45 | 22 |
| 40×2000 | 40 | 2000 | 32 | 480 | 260 | 420 | 37 | 22 |
| 40×2500 | 40 | 2500 | 32 | 520 | 290 | 500 | 55 | 22 |
| 40×3000 | 40 | 3000 | 32 | 560 | 290 | 500 | 55 | 22 |
| 40*4000 | 40 | 4000 | 32 | 660 | 360 | 650 | 75 | 22 |
| 50×3200 | 50 | 3200 | 40 | 650 | 380 | 700 | 75 | 22 |
| 50*4000 | 50 | 4000 | 40 | 780 | 440 | 820 | 90 | 22 |
| 60×3000 | 60 | 3000 | 50 | 710 | 420 | 780 | 90 | 22 |
| 60*4000 | 60 | 4000 | 50 | 840 | 480 | 920 | 110 | 30 |
| 60*5000 | 60 | 5000 | 50 | 940 | 520 | 1000 | 110 | 30 |
Structure and main parts
The W11S series 3-Roll Plate Rolling Machine is mainly composed of an upper roller device and upper roller position detection device, horizontal movement device and detection device, lower roller device, idler adjustment and detection device, main transmission device, tipping device, balance device, lubrication device and side frame, Chassis and other parts.
Upper roller and upper roller position detection device
- The upper roller device is mainly composed of a top roll, the main oil cylinder, a top roller bearing seat, and a double row self-aligning roller bearing.
- The upper roller device is used to provide the main pressing force 690Tons of the rolled plate. The main cylinder is a flange-type hydraulic cylinder and the piston rod adopts a YX-type seal with minimal leakage.
- The upper roller fixed side bearing seat and the inverted side bearing seat are each equipped with double row self-aligning bearings. The bearing seat is screwed to the main oil cylinder.
- The lifting amount at both ends of the upper roller is detected by the sensors located on the piston rod and the frame in the upper roller cylinder and displayed by a digital display. Both ends of the upper roller are not parallel with each other by less than 60mm.
Horizontal moving device and detecting device
The entire device is driven by a YEJ160L-4, 15kW, 1460rpm motor to drive a CWU140-10-IIIF worm gear reducer. The generated torque is transmitted to two pairs of worm gear reduction mechanisms, which in turn act as nuts to move the horizontal screw. The rack is moved so that horizontal movement of the upper roller is achieved.
The upper roller horizontal movement device is designed to pre-bend the end of the plate to achieve asymmetrical rolling when the upper roller is moved to change the horizontal position of the upper roller when asymmetrical rolling is realized.
The horizontal movement of the upper roller is detected by the displacement sensor mounted on the frame and the chassis, and the digital display shows the displacement. When the upper roller is in the middle position of the two lower rollers, the number should show zero.
Lower Roller Device
The lower roller device consists of a lower roller bearing seat, a lower roller, and a lower roller gear.
The lower roll device provides positive and negative torque to the rolled sheet.
Roller adjustment and detection device
The roller device is composed of a roller, a roller bearing seat, a connecting frame, an inclined iron, etc. Each under roller has two supporting rollers. Double rollers are respectively arranged inside the roller bearing seats at the journal ends of the roller. The self-aligning bearing reduces friction and the lift of the idler is driven by a YEJ132M1-6, N=4kW electromagnetic brake motor via a V-shaped V-belt A (L=1250) to drive a SCWU160-63-II reducer. The machine transmits torque to the screw rod. The left and right threads on the screw rod drive the connecting frame to move the four diagonal irons under the roller bearing seat.
When the thick plate is rolled, in order to prevent the lower roller from bending, the product roll is prevented from being made into a “purse” shape, and the support roller needs to be raised; when the thin plate is rolled, the product roll is prevented from being formed into a “girdle” shape and the support roller needs to be lowered.
The amount of lift of the roller is detected by a displacement sensor mounted on the inclined iron and the chassis and then displayed by a digital display.
Main Drive
The main transmission consists of a YZR315M-10 75kW 580rpm main motor, YWZ-400/180 brake and main reducer.
The D-type V-belt is connected between the motor and the speed reducer. The main reducer is a five-stage transmission. The transmission ratio of each stage is 3.37, 4.28, 4.28, 3.16, and 1.17 respectively. The total transmission ratio is 227.1, and the center distances of the first to fifth levels are 254, 385, 484, and 560, respectively. The modules are 6, 8, 10, 14, and 22, and the torque generated by the main reducer is transmitted from the output gear to the two lower rollers with m=22 and Z=28.
Overturning device
The overturning device consists of a single-stage cylinder (stroke 1390mm), a ram, a base, and the like.
The overturned side frame is tipped over, making it possible to remove the product.
Balancer
The balance device consists of two tie rods and a balance beam.The balancing device presses the tail of the upper roller after the inverted-side frame is tipped over to maintain the balance of the upper roller.
Balancer
The balance device consists of two tie rods and a balance beam.The balancing device presses the tail of the upper roller after the inverted-side frame is tipped over to maintain the balance of the upper roller.
Lubrication device
- Lubrication of this machine is achieved by manual dry oil pumps, grease guns, oil sumps, and manual refueling. The lubrication points are supplied as follows:
- Manual dry oil pump: upper roll bearing housing and frame vertical guide surface
- Move the ram horizontally and the chassis guides a surface
- Lower roller bearing
- Upper roller bearing (fixed side)
- Roller adjustment device, oblique iron, and copper wire mother
- Grease gun: upper roller bearing (overturn side)
- Roller bearing
- Lower roller gear and reducer output gear
- Oil Pool: Main Reducer
- Worm gear reducer for horizontal movement
- Horizontally moving worm gear mechanism
- Worm gear reducer with worm gear