Hydraulic Section Rolling Machine: How to make metal materials perfectly formed?

1. Working principle: perfect integration of hydraulic system and mechanical structure

The hydraulic section rolling machine converts hydraulic power into precise section bending force through ingenious system design. Its working principle can be divided into three stages:

• Hydraulic power generation system

The variable piston pump is used to provide high-pressure oil flow (working pressure is usually 21-32MPa)

The proportional valve group accurately controls the movement speed of the cylinder (adjustment accuracy ±0.1mm/s)

The accumulator compensates for the instantaneous flow demand and maintains stable pressure (fluctuation ≤5%)

• Three-roller collaborative working mechanism

Upper roller (active roller): driven by hydraulic cylinder, exerts the main forming force (single cylinder pressure can reach 400 tons)

Side roller (driven roller): adjustable position, control bending radius (electric or hydraulic adjustment)

Idler (support roller): prevents the instability of the profile, the number is configured according to the length of the profile

• Closed-loop control process

Pressure sensor monitors forming force in real time (range 0-50MPa, accuracy 0.5%FS)

Encoder feedback roller position (resolution 0.01mm)

PLC dynamically adjusts parameters according to preset curve (minimum bending radius can reach 1.5 times profile height)

Typical working cycle shows that the equipment can complete 90° bending of 6-meter-long H-beam within 90 seconds, with a repeatability accuracy of ±0.5°, which is much higher than the ±2° standard of traditional mechanical equipment.

2. Technical Features Analysis

The hydraulic profile rolling machine solves the technical difficulties of complex profile forming through a number of innovative designs:

Adaptive hydraulic system

The load-sensitive pump adjusts the flow rate according to actual needs (energy saving 30-40%)

The pressure compensation valve ensures the synchronization accuracy of multiple cylinders (deviation <0.2mm)

The overload protection valve automatically unloads when overloaded (response time <10ms)

Modular roller system design

The quick-change roller sleeve system supports the replacement of roller sets within 30 minutes

The roller surface hardness is HRC55-60, and the wear life exceeds 100,000 times

Special profile rollers (such as grooved and spherical) can cope with special profiles

Intelligent control system

The 7-inch touch screen stores 100 sets of process parameters

Automatically calculate the rebound compensation amount (based on the material database)

Three-dimensional simulation of the bending process, collision warning

Enhanced structural frame

Integral steel plate welding, finite element optimization (static stiffness>1×10⁵N/mm)

Prestressed tie rod eliminates joint gap

Guide rail surface quenching treatment (hardness HRC58-62)

Multifunctional auxiliary device

Laser centering system (accuracy ±0.1mm)

Automatic lubrication unit (timing and quantitative oil injection)

Hydraulic support rack (adjustable load 2-5 tons)

Safety protection system

Grating protection (response time 4ms)

Emergency return button (fast pressure relief of the entire system)

Oil temperature monitoring (alarm over 65℃)

3. Advantages compared to traditional equipment

Hydraulic profile rolling machine surpasses traditional mechanical rolling equipment in multiple dimensions:

• Breakthrough in forming capacity

High-strength steel can be processed (yield strength up to 960MPa)

Minimum bending radius is reduced to 1.2 times the profile height (traditional equipment requires 2 times)

Asymmetric cross-sections (such as C-shaped steel) are formed in one go

• Comprehensive improvement in accuracy

Angle control accuracy is improved by 4 times (±0.5° vs ±2°）

Ovality <1.5% (conventional 3-5%)

Non-indentation forming (surface roughness Ra <3.2μm)

• Leap in production efficiency

Changeover time shortened by 70% (30 minutes vs. 2 hours)

Bending speed increased by 50% (line speed up to 6m/min)

Continuous working capacity enhanced (24 hours non-stop)

4. Operation specifications and safety points

The following key points need to be mastered for the correct use of hydraulic profile bending machines:

• Start-up preparation process

Check the hydraulic oil level (should be at 2/3 of the window)

Preheat the hydraulic system (run 10 minutes without load in winter)

Verify the function of each limit switch

Select a matching bending mold

• Typical operation steps

Enter material parameters (material, specification, strength)

Set target curvature radius/angle

Automatically calculate the initial position

Trial bend and measure actual size

Enter compensation value for secondary precision bend

Complete part 3D scanning comparison

• Key parameter control

Bending speed: 3-6m/min (adjusted according to material thickness)

Pressure holding time: 10-30 seconds (eliminate rebound)

Feed amount: 1-3mm each time (precision control)

• Safety precautions

Over-specification processing is strictly prohibited (comply with the equipment capacity table)

The profile must be completely inserted into the roller before starting

Immediately stop and check if there is abnormal noise

Unified command signal when two people are operating