A Plate Roller is a piece of industrial equipment that can bend flat sheets of metal into type shapes, (cylindrical, conical and/or curves). These machines are utilized within various Heavy Fabrication Industries to manufacture tanks, Pressure Vessels, Pipes, Silos, and various other types of Structural Components.
The process of rolling a plate into a cylinder is accomplished by having the metal plate move through a set of rollers that controlled pressure is applied and allowing the curvature to be gradually formed. Plate rolls come in different levels of automation including manual, hydraulic, and CNC, depending on the required thickness capacity, level of automated operation, and production specifications needed by the user.
Main Components of a Plate Rolling Machine
For accurate metal fabrication through multiple mechanical and hydraulic component functions, the plate rolling machine contains top and bottom rollers as the main rollers which apply controlled force into the rolled plate to form the desired radiuses or curve in the metal part. A heavy duty fabricated steel frame provides the machine with adequate rigidity and stability when operating under high load conditions. The hydraulic system provides sufficient force to both move the roller into the desired location as well as to apply bending force onto the rolled plate, while the drive system and electric motor supply the power required to efficiently rotate the rollers. All roller torque and roller speed is accurately controlled through the use of the drive system gearbox and transmission. More advanced models of plate rolling machines offer precision rolling cycles based on the use of CNC control panels which enable the plate rolling machine to roll plates with superb accuracy and repeatability. In addition there are side supports and feeding tables available for improved productivity by properly handling the damage caused by large and heavy plates through the plate rolling process.
Working Principle of Plate Rolling Machine
A plate rolling machine operates on the principle of progressively deforming a piece of metal through the application of compressive force from the rollers that are positioned above and below the plate being rolled. The plate is placed into the machine so that it lies in between two rollers (top and bottom). As the rollers continuously turn, they pass through the plate while simultaneously applying a compressive force on the plate in order to create a bend. On a three-roll machine, the top roll moves up or down to provide the correct amount of tension as needed to bend the plate. On a four-roll machine, the extra top roll will help maintain accurate alignment of the bottom rolls and also adds additional bending capacity and pre-bending capability. The operation requires multiple passes through the rolling machine until the desired radius is reached. The radius generated by the rolling machine varies both with the thickness of the plate being deformed, the strength of the material of the plate being deformed, and the position of the rolls relative to each other.
How is a Plate Rolling Machine Manufactured?
The construction of plate rolling machines is based on a series of engineering procedures that are used to guarantee that these machines can withstand maximum stress and perform accurately over long periods. The first phase is an extremely detailed design phase, based on complete engineering using sophisticated Cad systems, where all aspects of the machine, including roll diameters, load capacities, and other structural issues, are assessed before any physical construction begins.
Once the detailed designs have been completed and are ready for manufacturing, high strength steel plates will be manufactured using cutting, welding, and assembling techniques to build a rigid frame, which will then receive stress relieving treatments to remove any internal stress from the welding process.
Next, the rollers, shafts, and mounting surfaces will be precisely machined to ensure proper alignment and smooth movement of all components during operation. After machining is complete for all parts of the machine, assembly of the machine including mechanical & hydraulic components (e.g., cylinders, motors, gear boxes, controls) will take place.
After assembly is completed, thorough testing (with a loaded test condition) and calibration will occur on the finished machine by Plate rolling machine manufacturer so that it can operate consistently for its expected life and meet all safety standards for rolling materials.
Where is Plate Rolling Machine Manufactured in India?
- Principal cities throughout India produce plate rolling machinery including:
- Rajkot (manufacturing sector);
- Ahmedabad (mechanical and heavy equipment engineering/ Industrial Systems);
- Coimbatore (machine tool industries) – also, there is a very mature supply chain of goods and services
- Pune (industrial and automotive);
- Faridabad (heavy machinery and fabrication / manufacturing).
All of these cities produce product natures similar to that of Plate Rolling Machines and have a dense concentration of skilled people, advanced infrastructure to fabricate, and reliable supply chain for both hydraulic and mechanical components.
Applications and Uses of Plate Rolling Machine
Plate rolling machinery has become popular among different heavy engineering industries such as pressure vessels, tanks, pipes/tubes, wind towers, ships, boilers, structures and oil & gas equipment, due to the necessity for machines that can accurately shape plates into circular/cylindrical or semi-circular shapes with predetermined radius/curvature dimensions in a prescribed manner of consistency with regard to both bend and design tolerances; and to produce high-strength, large diameter and structurally sound components.
Conclusion
A plate rolling machine is a primary machine used in heavy fabrication to roll flat sheets of metal into cylindrical or curved shapes. Features of plate rolling machines include strong construction, complex hydraulic systems and optional CNC machines; all assist in the production of precise parts and ensure durability and high efficiency of production. Produced in some of the best industrial areas in India, plate rolling machines have become an essential part of various industries such as oil and gas, industrial construction, shipbuilding and heavy engineering, all contributing to modern infrastructure and industrial development.
