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A plate rolling machine makes cylindrical, elliptical, and spherical shapes from metallic plates. Buyers can find many types of rolling machines based on the working principle, number of rolls, machine structure, controller, and plate rolling machine capacity.
Working Principle
The rolling machines can be classed based on their working principles. The 3 main types are bend, draw, and push. The draw and push machine types have horizontal axles. They mainly use clamps and conveyors to draw the plates through the rolling axle. Between Draw and Push, the draw machines are usually faster in processing speed.
Roll Number
Depending on the number of rollers, machines can be categorized into four-roll and three-roll plate rolling machines. Generally, the four-roll machine offers better accuracy and stability than the three-roll machine. While the machines have one central rolling axle and two support axles, the four-roll machines have two central rolling axles. One of the central rolling axles moves down to help place the metal plate better.
Machine Structure
The machines have different structures that determine how well they work with curved lines. The flat line curves can find different intersections based on how the lines and curves meet each other.
The guide machines work with a belt and blocks to push the plate into the rolling area. They are an economical choice for businesses and trainees using softer materials. In contrast, the pyramids and cone machines can process materials faster and better because they have intersecting lines that form a cone. They are more suitable for professional use with hard metal materials. The conical machines can also form a cone shape by tilting the side cylinders.
Machine Controllers
An automatic machine will roll the plates more consistently and precisely than manually or motor-driven machines. Manually driven machines may need more personnel to perform tasks, while autonomously driven machines can roll without much manual labor.
Rolling Capacities
Customers can find materials with different rolling capacities. Some have a high capacity for rolling thicker material plates, while others are better for rolling thinner ones. Machines with a high rolling capacity will have larger motors. For example, it will have a 75 kW motor versus a 30 kW for the smaller motors.
A roll plate machine's specifications can vary depending on the type of machine and model; however, the following are standard specifications for plate rollers.
Capacity
It refers to the thickness and width of the metal plates the machine can roll. For instance, a standard three-roll plate rolling machine may have capacity rolling plates up to 25.4 mm (1 inch) thick and 3,048 mm (120 inches) wide.
Roll Diameter
The roll diameter affects the amount of force needed to achieve rolling. Generally, larger rolls apply more force to bend thicker plates. The roll diameter for plate rolls can range from 200 mm to above 1,200 mm.
Overall Dimensions
Overall dimensions include the length, height, and width of the machine, as well as the net weight. For example, overall dimensions for a typical machine are 4,000 x 2,000 x 2,000 mm with a net weight of 6,500 kg.
Power and Torque
Power and torque specifications depend on the motor driving the plate rolls. A typical power motor rated is 15 kW, producing a torque of 22,000 Nm.
Like any other industrial machine, the plate rolling machine requires regular maintenance to ensure optimal performance. Operators should follow the manufacturer's recommendation to keep the machine in good shape and avoid sudden breakdowns that can cause hazards or downtime.
Routine inspections should focus on identifying areas that require lubrication, tightening, or parts that need replacement. During inspections, pay close attention to the bearings, gear boxes, chains, and drives. These areas are frequent with lubrication and may also need a small, specialized, and discreet oil that goes a long way.
Look for loose or worn-out parts like belts and chains that may require adjustment or replacement. Check for any signs of dirt and debris buildup and take measures to keep the area and equipment clean. Regular pressure washing can help remove any residue buildup that can lead to damage or corrosion.
In some cases, manufacturers provide details on the areas of the machine that receive lubrication, but for most machines, it's common to see bearings and other moving parts that constantly work under friction.
Operating the rolling machine shouldn't be a hassle for anyone who understands the simple processes involved in rolling plates. Even so, it's critical to ensure bolt fasteners and nuts are properly tightened on crucial machine areas, including gears and chains. Notably, longevity is determined in part by the frequency of maintenance and the use of quality lubricants and oils.
If unsure about the areas that need maintenance, consult the machine's manual or a professional technician who can provide insight into the maintenance needs of the specific plate rolling machine being used. Proper maintenance not only improves the lifespan of the plate roll but also ensures the safety of operators during use.
Because of their capacity to carry massive plates, rolling machines are popular in numerous industries.
Construction
In the construction industry, the rolling machine is used to bend plates into beams, barrels, tanks, and pipes for bridges and architectural structures. The structures eventually need to have their materials bent. This machine becomes handy and useful at this point. It's easy to roll sheets into cylindrical-shaped structural elements such as columns, particularly for less thick plates.
Shipbuilding and Marine
Plate rolling machines are the backbone of the shipbuilding and marine industries. These machines create the hulls, decks, and bulkheads by rolling steel plates into complex shapes. All these, ensuring structural integrity and seaworthiness.
In this industry, template, hydraulic, and CNC machines are preferable. This is due to the requirement of precision and automation as mandated by international maritime standards. Whereby, sea vessels must adhere to certain standards and regulations. Here, automated machines are ideal, as they guarantee consistent results while minimizing human error.
Automotive and Transportation
In the automotive industry, plate rolling machines are tasked with creating body components such as chassis, frames, and wheel arches. Automotive manufacturers mainly use CNC machines for easy-to-change programs and high-precision control.
Oil and Gas
The energy sector relies on plate rolling machines to construct components like pressure vessels, storage tanks, and pipeline sections. Such are key elements in oil and gas exploration and refining operations.
Aerospace and Aviation
The aerospace industry is very precise. Here, machines are used to shape lightweight but strong materials such as quick and stainless steel, aluminum, and titanium into aircraft structures, fuselage sections, and wing components. The choice of machine in this industry most depends on load capacity and precision.
Because the aerospace field is strict, only the aerospace industry can afford the more advanced plate rolling machine models. For one, the machine may have a higher rolling capacity. Other aspects, including strength, thickness, and the plate's diameter, may also be advanced. Furthermore, there's need for automation and precision. As a result, only machines with the latest technology and features will do to meet the required specifications.
Consider the material and thickness:
Knowing the type and thickness of the material is very crucial for selecting the plate rolling machine. Some machines can only roll steel plates of a specific thickness. Moreover, having the correct plate thickness will narrow down the choices.
Think about the size and capacity:
The width of the machine must be enough to accommodate the plates. In terms of capacity, it's important to consider the weight of the heaviest plate that will be rolled. Buyers can choose between three-roll plate rolling machines and four-roll plate rolling machines, depending on their requirements.
Think about the end product:
Different machines produce distinct shapes and dimensions. Consider the required shape and dimension before selecting a rolling machine.
Ease of Use:
Some machines are easier to operate than others. Consider the skill level of operators and choose a machine that is appropriate for their training and experience.
Energy Efficiency:
Consider the energy efficiency of the machine and choose an energy-efficient model to reduce operational costs.
Q: What materials does a plate rolling machine roll?
A: The primary materials that roll plates are commonly used to roll, including steel, aluminum, stainless steel, copper, brass, and other alloys.
Q: Is training necessary before operating a plate rolling machine?
A: Yes, prior to operating the machine safely and effectively, training may be necessary because of the complexity and size of the rolling machines.
Q: What's the difference between a plate rolling machine and a bending machine?
A: While a plate rolling machine is designed primarily to create curves and rolls in sheets of metal, machines are more versatile and can perform a variety of operations including changing the shape of the metal into arcs,U-shapes, and V-shapes. Moreover, the rolling machines typically use cylinders to apply pressure to the metal, whereas bending machines rely on a combination of heat and compression.
Q: Can a plate rolling machine create conical shapes?
A: Yes, there are machines that can roll plates into cones. They have an adjustable top roll which allows the material to be tapered at one end.
