1 Hydraulic control ROLCOX

of the rolls

Fixed Roller

Left Right

Movable Roller

Next Pump HD 1 M 01

Hydraulic oil tank

 Left Right HD1 M 01 Hydraulic pump
2
Fixed Roller Next
HD1 V 1/2 Prop. valve left
Retraction cylinder Retraction cylinder Next

HD1 V 3/4 Prop. valve right

Next
Pressure decrease valve left
Movable Roller HD1 V 09
( one way valve )
Next
Press cylinder Pressure decrease valve right
HD1 V 10
( one way valve )
Next
V 05 V 08 V 06
HD1 V 07 Retraction cylinder valve
V 09 V 10
Next

HD1 V 05 Bypass valve left

Next
V 1/2 V 3/4 HD1 V 06 Bypass valve right

Next
V 07 HD1 V 08 Emergency valve

Pump HD 1 M 01

Hydraulic oil tank Next

 3
Roller dist. = 10 mm fix
+ Bearing dist. = 0 mm Next
Next
Next
Next
Gap = 10 mm
measured by

Gap sensor Limit switch

RP - Frame

Retraction cylinder
Press cylinder

Fixed Bearing Movable Bearing

Distance block

Next
 Set points 4
Fixed Roller

Gap = 10 mm
Distance pieces L 0mm 0 mm ( Bearing distance )
Next
Left Right This is the point where the bearing distance is 0.
For the gap measuring this point is 4 m Amp.
Movable Roller The bearing blocks are fixed in a way that the
rollers can never touch each other physically

Roller distance 10mm = Gap 10 mm

Next

L min 15 mm ( Bearing distance )

Distance between the bearings used as lower
limit for the pressure control.
Fixed Roller If distance is less pressure control will be Next
deactivated.
Left Right
Gap = 25 mm
GAP < L min Pressure control OFF

Movble GAP > L min Pressure control ON

Movable Roller normal operation
Roller
Next
Roller distance 10 mm
+ Bearing dist. 15 mm
= Gap 25 mm
Next
 Set points 5

Fixed Roller distance 10 mm

+ L2 Bearing dist. 25 mm
Left Roller Right
L min = Gap 35 mm
Gap = 35 mm
L2
Parameter set in the PLC. Set only once.
Range from 5.0 to 30.0 mm
Actual set point 25 mm
Movable ( Set point for material feeding )
Roller Next
Next

Roller distance 10 mm
Fixed + L2 + 10 Bearing dist. 35 mm
Left Roller Right = Gap 45 mm
L min
Next
Gap = 45 mm L2
+ 10 mm
Until this value the rollers are pushed back
during start up the main motors.

Movable
Roller
Next
 6
Set points

Fixed Roller distance 10 mm

Left Roller Right + Bearing dist. > 55 mm
L min = Gap > 65 mm
Normal operation L2
Gap = 65 mm maximum Next
+ 10 mm
Movable Limit switch
Movable
Roller
Movable Maximum distance allowed
Roller between the bearings. ( 65 mm Gap )
Movable
Roller Determined by a mechanical switch.
Roller Over 65 mm gap the roller press will
stop with max. gap alarm.

Ok.

Next
 7
Start RP group
Fixed
Left Roller Right
Gap = 45 mm At every start the emergency valve is energized
to close the hydraulic circuit.
Next
Next
Movble
Movable To release the oil of the main cylinders the bypass valves
Roller and the pressure decrease valves are energized (opened).
Roller
This will occur with standing rollers.
NextNext
Press cylinder
The movable roller will be moved
by the retraction cylinders to L2 + 10 mm = 45 mm
V 06
05 08
V 09 V 06
07
10
V 09 11
V 10 Next
Next
L min
L2
+ 10 mm
V 1/2 V 3/4
V 07
After reaching of L2 + 10 mm, the main drives will be
started one by one.

Valve closed
Pump HD 1 M 01

Hydraulic oil tank Valve open Next

 Start RP group 8
Retraction cylinders are drawn back by springs.
Fixed
After this the movable roller will be pushed back to
Next
Left Roller Right L2 by the main cylinders from 45 mm to 35 mm.
This happens with running rollers.
Gap = 35
45 mm Next

L2 Gap = 35 mm Next
Movble
Movable
Roller In case if during moving back the movable roller an oil pressure
Roller is measured of more than 40 bar ( normal < 40 bar ), the start will
be interrupted by an alarm signal.
Press cylinder Fault has to be acknowledged at the roller press after checking.

Possible causes:
Material between the rollers.
V 06
05 08
V 09 V 06
07 Disturbance in the hydraulic circuit.
V 10
09 V 11
10
Roller can not move free.

After bearing distance is on both sides L2 the roller press group will
be released and feeding of the pre bin can be started.

Next
Pump stops and valves will be closed.
V 1/2 V 3/4

V 07
08 After L2 will be reached in pre bin the shut off Gate will be opened
to release material flow to the rollers.

Pump HD 1 M 01

Hydraulic oil tank Next

 9

Fixed Roller
Start Pressure control
Left Right After the start program is ready the pressure
control will start automatically.
Next

After opening of the shut off gate there will get

Movable Roller material between the rollers.

Next
Press cylinder
The proportional valves will increase pressure to the
main cylinders up until the set point.
V 05 V 08 V 06 Hydraulic pump start.

V 09 V 10

V 1/2 V 3/4
V 07

Pump HD 1 M 01

Hydraulic oil tank Next

 10
Fixed Roller
Left Right

Pressure control
By the intake behaviour of the running rollers
combined with the pressure of the column ( gap )
Movable Roller
of material on the rollers the material flow will
tend to press the rollers apart.
Press cylinder
When the hydraulic reaches the
value set point-tolerance
V 05 V 08 V 06
the proportional valves will be closed
and the pump will stop.
Next
V 09 V 10

+ 10 bar
Pres.Set point
V 1/2 V 3/4
V 07
- 10 bar

At this value the material counter pressure

and the cylinder pressure will be on balance.

Pump HD 1 M 01

Hydraulic oil tank

Next
 11
Left
Fixed Roller
Right
Pressure control
Pressure variations with in tolerance will be
compensated by the N2 accumulators.
100
90
bar Next
Accumulator
100 bar
Gas ( N2 ) Pressure = 90 bar
Movable Roller
Start up
125 bar
Press cylinder < 90 bar

Set point 125 bar

V 05 V 08 V 06
135 bar
125 bar
V 09 V 10
115 bar

V 1/2 V 3/4
V 07

Pump HD 1 M 01

Hydraulic oil tank

Next
 12
Pressure control
Fixed Roller
Left Right When the hydraulic exceeds the pressure (value)
set point + tolerance the proportional valves will open and the
pressure decrease valves will be opened (energized).
135 bar
Next
125 bar
115 bar
Movable Roller They will remain open until the set point
operation pressure + tolerance is reached.
Press cylinder After this the valves will be closed.
Note: This can happen at both sides at the same time but also
on one of both sides, depending of pressure measurement on
V 05 V 08 V 06
this side.
Next
20 m Amp
V 09 V 10
11
Proportion valve
pressure
Characteristics of proportional valves. increase

V 1/2 V 3/4
V 07

100 30 %
%
V 10
12 m Amp 100
Proportion valve 0% %
pressure
decrease 8 m Amp
Pump HT 1 M 01 Set point
30 %
Hydraulic oil tank

4 m Amp Next
 Pressure control 13
Fixed Roller When the hydraulic gets beneath the pressure (value)
Left Right set point – tolerance the proportional valves will be
opened and the pump will start.

135 bar
125 bar
115 bar
Next
Movable Roller This will remain so until set point operation pressure – tolerance
has been reached.
Press cylinder After this the valves will close again and pump will stopped.
Next
In this example on one side.
V 05 V 08 V 06
20 m Amp
Proportion valve
V 09 18,4 m Amp pressure
V 10
increase
80 %
Characteristics proportional valves.
V 1/2 V 3/4
100
%
V 07 12 m Amp 100
V 09 V 10 Proportion valve 0% 80 % %
pressure
decrease

Pump HD 1 M 01

Hydraulic oil tank

4 m Amp

Next
 Gap correction 14
A deviation in gap width between left and right
in permitted until a preset value.
Fixed Roller Next
Left Right
A certain deviation is due to non homogenate mixture
Gap (r) of raw materials (coarse, fine, wet, dry).
Gap (l)

Gap (l) = Gap (r)

Movble
Roller Roller
Movable If this value is exceeded the skewing will be corrected.

Press cylinder
Presscilinder
Gap(l) - Gap(r) = Gap(diff)
V 05 V 08 V 06
Gap(diff) > Gap(diff)toll.
V 09 V 10
Correction will be done first on the side with the bigger
gap by pressure increasing.
V 1/2 V 3/4

Correction is permitted until operation pressure + 5 bar.

V 07 This will remain so until gap - difference - tolerance

V 09
has been reached. Set point 4 mm.
Next
After this the valves will close again and pump will stop.
Pump HD 1 M 01

Hydraulic oil tank

Next
 15
Gap correction
Fixed Roller
Left Right
Gap (r)
Gap (l)

Movble
Movable
Roller Roller
If skewing is after this correction still not within
tolerance limits, at the side with the smallest gap,
Press cylinder
Presscilinder pressure will be released.

V 05 V 08 V 06
This will remain so until gap - difference - tolerance
has been reached. Set point 4 mm.
V 09 V 10
11
Next

After this the valves will close again.

V 1/2 V 3/4

V 07
V 09

Pump HD 1 M 01

Hydraulic oil tank

Next
 16
Fixed Roller
Left Right
L(l) L(r) Gap correction
and Pressure Control
Movble
Movable
Roller Roller
Gap (diff) < Gap (diff)toll. ( 4 mm )
Press cylinder
Presscilinder

After this correction pressure control will be reactivated.

V 05 V 08 V 06
Next

V 09
10 V 11
10 If pressure difference between left and right exceeds a
preset maximum ( 30 bar ) an alarm will be generated
and pressure will be released at both sides.
Next
V 1/2 V 3/4

V 07

Pump HD 1 M 01

Hydraulic oil tank

Next
 17
Fixed Roller Current control
Left Right

By means of to much adjusting of operation pressure or

due to changing material properties
the electrical load of the main drives can become to high.
Movable Roller If this load exceeds a preset maximum the pressure will
be reduced.

Press cylinder This will last until the movable roller reaches Next
L2 + 10 mm = 45 mm gap
or until the drives get below operation load.
V 05 V 08 V 06

V 09
10 V 11
10

After this the pressure control will be reactivated.

V 1/2 V 3/4

V 07

Pump HD 1 M 01

Hydraulic oil tank

Next
 18
Fixed Roller
Fix Roller RP Group stop
Left Right
At a stop of the roller press (desired or undesired)
the RP - slide gate will close and
stopped the material feed to the RP.
Movble
Movable Roller
Roller The Pressure decrease valves will open,
the proportional valves will open, Next
and the emergency valve will open.
Press cylinder

V 05 09
V 08 V 06

The rollers will due to material pressure move apart

V 09
10
V 10
11 until L2 is reached on both sides or after time limit.
Roller press will stop after 30 sec.

V 1/2 V 3/4

Next
V 07

The Pressure decrease valves will close,

the proportional valves will close,
Pump HD 1 M 01 and the emergency valve will open.

Hydraulic oil tank Next

Roller press
Dosing Gate 19
RP - Bin
Slide Gate.
opened
close
open

Dosing
Gate in
max. Pos.
min. Pos. Open
Dosing the
Gate Dosing
Fixed Gate
Roller

Movable
Roller

Last
20