How to roll round the plate rolling machine?

The"fast and good"round rolling of the plate rolling machine is a systematic integration of equipment accuracy,process scientificity,and operational standardization.From laser pre bending to digital twin,from pressure closed-loop control to robot collaboration,technological innovation is constantly breaking through the physical limitations of traditional processing.For manufacturing enterprises,through the three-dimensional drive of"equipment upgrade+process standardization+skill digitization",they can achieve quality improvement while increasing production capacity,and build core advantages in fierce market competition.

1.Type selection of plate rolling machine
Three roll symmetrical coiling machine:suitable for coiling medium and thick plates(6-50mm),with synchronous lifting design of the lower roll to reduce the number of pre bending times.A factory's actual test shows that using the W11S-120×3000 three roll machine to roll 12mm thick Q345R steel plate reduces the processing time of a single piece by 18%compared to a four roll machine.
Four roll plate rolling machine:Its advantage lies in high-speed rolling of thin plates(<6mm),and its side rollers can move independently to achieve pre bending.A certain electronics factory uses the W12-16×2500 four roll machine to roll 2mm stainless steel plates,with a speed of 8m/min,which is 40%higher than the three roll machine.
2.Upgrading of key components
High rigidity roller shaft:Made of 42CrMo alloy steel quenched and tempered,with a hardness of HRC28-32,it can withstand a bending stress of 2000kN/m and reduce roundness errors caused by deformation.
CNC system selection:Equipped with Siemens 840Dsl system,the bending machine can achieve closed-loop control of bending radius and feed rate.After application in a petrochemical equipment factory,the product qualification rate has increased from 82%to 97%.
3.Innovation of auxiliary tools
Laser pre bending guidance device:By projecting laser lines to mark the pre bending position,the operator's pre bending error is reduced from±15mm to±3mm.
Automatic feeding platform:using synchronous belt conveyor driven by servo motor,combined with magnetic separator,to achieve automatic positioning of sheet metal,and shorten the clamping time of single piece from 5 minutes to 1 minute.

Standardization of operational techniques:from experience dependence to skill replication

1.Control of pre bending process
Three point positioning method:Mark points A,B,and C on the edge of the board(A as the starting point,B distance A=1.5t,C distance B=2t),and adjust the side roller to make point B contact the lower roller line to achieve pre bending.
Residual compensation technique:Pre bending length L=π(R+t)/2+(10-15)mm,of which 10-15mm is the trimming allowance.After application in a certain pressure vessel factory,the straight edge length at the end was reduced from 35mm to 8mm.
2.Dynamic monitoring of the rolling process
Real time roundness detection:Laser profilometer is used to scan the edge of the board.When the roundness error is greater than 1mm,the side roller pressure is immediately adjusted.After application in a certain shipbuilding factory,the rework rate has decreased from 25%to 5%.
Acoustic emission monitoring technology:By analyzing the sound wave signals during the rolling process,cracks can be detected 0.5-1 seconds in advance,and a chemical equipment factory has measured a crack detection rate of 99.2%.
3.Integration of post-processing procedures
Online straightening device:A three roll straightening mechanism is installed at the outlet of the plate rolling machine to achieve continuous operation of"rolling straightening".The processing time of a single piece in a steel structure factory has been reduced from 45 minutes to 28 minutes.
Automatic marking system:using a coding machine to print batch numbers,bending radii,and other information on the rolled cylinder for easy traceability.After application in a nuclear power equipment plant,the quality traceability efficiency has been improved by 70%.
4、Typical case:Efficiency revolution in a petrochemical storage tank plant
1.Pain point analysis
Equipment aging:The roller shaft of the original W11-60×3000 plate rolling machine was severely worn,with a roundness error of 3.2mm.
Extensive craftsmanship:relying on the experience of experienced craftsmen,the training period for new employees can last up to 3 months.
Capacity bottleneck:The production capacity is only 12 units ofΦ3200×12mm storage tank barrels.
2.Renovation plan
Equipment upgrade:Purchase W11S-80×3200 CNC bending machine,equipped with laser pre bending guidance and automatic feeding platform.
Process standardization:Develop the"Q345R Steel Plate Rolling Process Card"to clarify the pressure and speed parameters for each pass.
Skill training:VR simulation system is used for operational training,reducing the onboarding time for new employees to one week.
3.Transformation effect
Efficiency improvement:The processing time for a single piece has been reduced from 75 minutes to 32 minutes,and the daily production has been increased to 28 units.
Quality improvement:roundness error is controlled within±0.8mm,and the first-time inspection pass rate has increased from 78%to 99%.
Cost reduction:Labor costs are reduced by 40%,and energy consumption is reduced by 25%.
Plate rolling machine in metal sheet processing,widely used in industries such as pressure vessels,storage tanks,and pipelines.The traditional rounding process often faces problems such as low efficiency,large roundness errors,and surface scratches.