How to properly maintain a four-roller plate rolling machine to extend its service life?

1. Daily maintenance points

Lubrication system management

Lubrication parts:

Upper/lower roller bearings, gearbox, hydraulic cylinder guide column.

Chains, guide rails and other transmission parts.

Lubrication requirements:

Use ISO VG220 or VG320 high temperature resistant grease.

Manual lubrication points: refill every 8 hours (such as bearing seat).

Automatic lubrication system: check whether the oil circuit is unobstructed and whether the oil pump pressure is normal.

Hydraulic system maintenance

Hydraulic oil management:

Replace every 2000 hours or 6 months (HM46 or HV46 anti-wear hydraulic oil is recommended).

Check the oil level and oil temperature (normal ≤60℃) to avoid impurity contamination.

Filter element replacement:

Inspect the oil suction filter element every 500 hours and replace the oil return filter element every 1000 hours.

Common problems:

Is the oil temperature too high? Check whether the cooler is blocked or the hydraulic pump is leaking.

Unstable pressure? It may be that the valve block is blocked or the seal ring is aging.

2. Maintenance of key components

Maintenance of rollers and bearings

Roller surface protection:

Clean the surface of the plate before processing (avoid welding slag and iron filings from scratching the roller surface).

Check the roller surface wear regularly, and use oilstone to polish minor scratches.

Bearing inspection:

Check the bearing temperature (normal ≤70℃) and abnormal noise every month.

Disassemble and inspect the bearings every 2 years and replace the grease.

Replacement standard:

Roller radial runout>0.05mm or bearing clearance exceeds the standard.

Electrical system inspection

Regular inspection items:

Motor insulation resistance (≥1MΩ).

Is the inverter cooling fan normal?

Is the limit switch and encoder signal sensitive?

Preventive maintenance:

Tighten the terminal every six months to avoid looseness and short circuit.

3. Operation specifications and fault prevention

Correct operation habits

Processing parameter control:

Overloading is strictly prohibited (such as rolling plates that exceed the nominal thickness of the equipment).

Avoid rapid reverse operation to reduce gear impact.

Common faults and solutions

4. FAQ about Four Roll Plate Bending Machine

• What is the main difference between a four-roller plate rolling machine and a three-roller plate rolling machine?

Structural differences:

The four-roller plate rolling machine has one more auxiliary roller (side roller) than the three-roller plate rolling machine, which can pre-bend the two ends of the plate and complete the rolling without turning around.

The four-roller plate rolling machine has higher forming accuracy (roundness error ≤ 0.5mm/m) and is suitable for high-precision processing.

Applicable scenarios:

Three-roller plate rolling machine: suitable for simple rolling and low-cost needs.

Four-roller plate rolling machine: suitable for precision processing such as pressure vessels, aerospace, etc.

• What materials can the four-roller plate rolling machine process?

Material range:

Carbon steel (Q235, 45#), stainless steel (304, 316), aluminum alloy, copper, etc.

Maximum thickness: usually 6-150mm (depending on the machine model).

Notes:

When processing stainless steel, the feed speed needs to be reduced to avoid scratching the roller surface.

For ultra-thick plates (＞80mm), a large torque model needs to be selected.

• How to solve the problem of straight edges at the ends of the plate when rolling?

Advantages of four-roller machine:

Pre-bending with side rollers can eliminate straight edges (three-roller machine requires additional U-turn processing).

Operation tips:

Pre-bend the ends of the plate first (press down 5-10mm with the side rollers).

Then roll the main roller to ensure that the curvature of the end is consistent with that of the middle.

• What should I do if the plate rolling machine vibrates violently during operation?

Possible reasons:

Unstable foundation (concrete foundation + shock-absorbing pads are required).

Roller bearings are worn or hydraulic pressure is unstable.

Solution:

Check whether the anchor bolts are loose.

Stop the machine to detect bearing clearance (＞0.1mm needs to be replaced).