Plate roller bending machine is a forming device that uses the relative motion of rollers to cause continuous plastic deformation of metal sheets, thereby forming cylindrical, conical, or arc-shaped work pieces. This content covers structural principles → operating procedures → parameter control → maintenance → fault diagnosis → safety regulations → management suggestions, and is applicable to three-roll/four-roll sheet metal rolling machines (W11/W12 series).

1. Overview of Plate Roller Bending Machines

1) Definition and Applications

Sheet metal rolling machines (plate rolling machines) are forming equipment that uses the relative motion of rollers to cause continuous plastic deformation of metal sheets, thereby forming cylindrical, conical, or arc-shaped workpieces.

Typical Application Industries:

- Sheet metal processing

- Pressure vessels

- Wind power/energy storage

- Machinery manufacturing

- Stainless steel products

- Chemical equipment

2) Common types and differences

High precision and high efficiency: Four-roll plate bending machine recommended.

2. Structural Composition and Working Principle

1) Main Structural Components Of Plate Roller Bending Machine

- Upper Roll: Main drive roll, providing winding power

- Lower Roll: Auxiliary clamping and driving

- Side Rolls (Four Rolls): Pre-bending and forming control

- Frame: Integral load-bearing structure

- Hydraulic System: Roller lifting and pressurization

- Transmission System: Motor, reducer, gears

- Electrical Control System: Buttons / PLC / CNC

- Lubrication System: Bearing and slider protection

2) Working Principle (Taking 4-roller bending machine as an example)

- Lower roll rises to clamp the sheet metal

- Side rolls rise to achieve pre-bending

- Upper and lower rolls rotate to complete winding

- Multiple cycles gradually form the sheet metal

- Adjusting the side rolls completes rounding.

3. Rolling Process and Detailed Operating Procedures

1) Technical Confirmation Before Use (Very Important)

Material Parameters:

- Material (Q235 / Q355 / SUS304 / Aluminum)

- Thickness

- Width

- Yield Strength

Work piece Parameters:

- Target Diameter

- Roundness Requirement

- Allowable Straight Edge Length

Equipment Capacity Verification:

Actual Rolling Thickness ≤ Rated Thickness × 0.85 (Recommended Value)

2) Standard Operating Procedure (Detailed Version)

Step 1: Equipment Inspection

- Hydraulic oil level ≥ 2/3 of the gauge

- No abnormal noise, no leakage

- Emergency stop, limit switches, and travel switches are normal.

Step 2: Loading and Centering

- Align the centerline of the sheet material with the center of the roller shaft

- The edge of the sheet material is parallel to the roller shaft

- Wide sheets must use brackets or auxiliary supports.

Step 3: Pre-bending (Critical Process)

- Four-roll:

One side roller rises → Pre-bend the first end

Turning direction → Pre-bend the second end

- Key Technical Points:

The amount of pre-bending determines the straight edge length

Insufficient pre-bending is the root cause of "straight edge length".

Step 4: Rolling and Forming

- Upper and lower rollers rotate

- Side rollers are fine-tuned in stages

- Multiple reciprocating rolling operations

- Each pressure increment ≤ 1–2 mm

- Do not press to the bottom all at once.

Step 5: Rounding

- Reduce the rotation speed

- Fine-tuning the side rollers

- Continuously roll 2-3 times

- Observe the change in roundness

Step 6: Unloading

- Completely release the hydraulic pressure

- Open the tilting mechanism (if applicable)

- Smoothly unload the work piece.

3) Summary of key points in process control

4. Maintenance and Care (Full Version)

1) Daily Maintenance (Per Shift)

- Clean roller surface and machine body

- Check hydraulic lines

- Wipe guide rails and lubricate

- Check buttons, foot pedal, and emergency stop

2) Weekly Maintenance

- Check bolt tightness

- Check lubrication supply to lubrication points

- Check reducer operating sound

3) Monthly Maintenance

4) Regular maintenance (monthly / quarterly)

5) Annual Maintenance

- Replace hydraulic oil

- Comprehensive bearing inspection

- Check roller parallelism

- Check frame deformation

6) Hydraulic System Management (Key Point)

- Recommended oil: 46# anti-wear hydraulic oil

- Initial oil change: 3 months / 500 hours

- Subsequent oil changes: 12 months / 2000 hours

- Recommended oil temperature ≤ 55℃

7) Roller And Bearing Maintenance

- Prohibit prolonged high-speed operation under no-load

- Polish minor scratches on the roller surface promptly

- Stop machine immediately and inspect for any abnormal vibration or response

5. Common Faults and System Diagnosis

6. Safety Regulations (Training Required)

1) Prohibited Actions

- Overload

- Reach hands between rollers

- Reverse emergency stop

- Striking between rollers

2) Must Be Followed

- Two people must operate large work pieces

- Wear protective gloves and shoes

- Stop the machine immediately in case of any abnormality