一、Security Explanation

1、Power supply
The input power supply of the machine is three-phase 3-380v 50Hz ac, the steady-state
voltage value is 0.9-1.1 times the rated voltage, the frequency is 0.99-1.01 times the
rated frequency, and the total input power is 70kW.The main power supply of the machine
is introduced from the user part (L1, L2, L3) at the bottom of the power cabinet.
2、Ground connection
The machine must have a good grounding connection device, before connecting the power
line, the protection ground must be linked. The total grounding connection of the machine
is on the cooper medal of the machine electrical cabinet and separate wires must be used
for safe grounding.All the moving parts of a machine tool must have jumper wires to protect
earth, grounding resistance should less than 4 Ω.
3、Environment
Working environment is between 5-40℃, no corrosive gas, liquid use.
4、Maintenance and repair
Regularly check the insulation resistance of each motor within the allowable
range.Periodically check the correct flexibility of each indicator, solenoid valve,
contactor and digital display meter.
PLC maintenance: check whether the BATT light in the CPU module is on every time you
start up. If the light is on, please replace the lithium battery in the CPU module within
a week, otherwise the internal program of the CPU will lose.The POWER lamp is the POWER
indicator, which is on when the POWER supply voltage of PLC is correct.The CPU light
is the CPU monitoring light. When the CPU is working normally, the light is in the off
state, and the RUN light is the indicator light for the PLC to work normally.Maintenance
must be carried out by professionals who have received technical training. Wet hands
are forbidden to touch the components of the machine.
5、Electrical installing and debugging
Connect each motor, solenoid valve, hand button and other wiring according to the
electrical external wiring diagram, and ensure the grounding reliability of each live
body, and adjust each thermal relay to a reasonable value.Only when the machine is
confirmed to be in good condition can each operation be carried out.Check motor direction,
limit direction and accuracy of each limit switch.
6、Labour protection
When professionals enter the site for maintenance, they must wear labor protection
products such as insulating boots etc.,before touching the components, they must use
a multimeter to check the residual voltage in case of danger.
二、Overview
The electrical system of the machine tool is designed according to the three-phase ac
power supply, the power supply voltage and frequency are suitable for 380V,50Hz.The
machine adopts programmable logic controller (PLC) control, its input power supply is
ac 220V, the contactor voltage is ac 220V, the solenoid valve voltage is ac 220V, ac
220V voltage is through the transformer (380V into 220V).The machine has three
motors.Main drive motor M1, oil pump motor M2, mobile motor M3.

三、Machine operation
I、Button operation

Emergency stop
When an emergency occurs,press it to stop the machine

Stop/start machine
After connect the main power,turn it to right to start machine.After finish
work,press it to left to cut off the power

Oil pump start

Before start machine,press it to start oil pump

Oil pump stop

After finish bending,press it to stop oil pump
Drop end open
Press it to open the hydraulic drop end

Drop end close

Press it to close the hydraulic drop end

Manual/auto model
Press it to left,in manual model
Press it right,in automatic model

Press to A,at same time push handle to up and

down to control A roll up and down.
Press to B,at same time push handle to up and
down to control B roll up and down.
Press to D,at same time push handle to up and
down to control bottom roll up and down

Press it,and push handle up and down,to control

the A roll fixed side up and down

Press it,and push handle up and down,to control

the A roll drop end side up and down

Press it,and push handle up and down,to control

the B roll fixed side up and down

Press it,and push handle up and down,to control

the B roll drop end side up and down
 Press it,and push handle up and down,to control
the bottom roll fixed side up and down

Press it,and push handle up and down,to control

the bottom roll drop end side up and down

Turn it to control the top roll rotate in forward and backward.

Cooperative this Slow button to control the rotate speed.

Press “SL”,the light in green,push handle up and

down to make release forward and backward

Press”LS”,the light in green,push handle to “star’

and up and down to make support rack
elevation.

Indicator of power connect

Indicator of start machine

 Indicator of oil pump start

Indicator of drop end closed to right position

Indicator of drop end open to right position

Indicator of fault

II、Touch Screen Operation

Operating instructions for touch screen of Hydraulics Arc Adjust Plate Rolling Machine
with 4 Rolls
Touch screen operation is combined with the console button and the operating handle.
All operations of the device are set on the touch screen and completed by the operating
handle or the button action. Please enter the password "2" before changing the parameters
in the touch screen.
 DG R

BG
AG

BF
AF

DF

Pictures of Plate Rolling Machine

Ⅰ.Boot Screen (as shown in picture 1)

中英文切换

Picture 1 Boot Screen

 Ⅱ、Manual Operation Screen (see picture 2)

a
b

e
d

Picture 2 Manual Operation Screen

1、a shows the current displacement, oil cylinder displacement [AG] at the fixed side
of roll A, oil cylinder displacement [AF] at the drop end side of roll A, and the rest
are similar.
2、b is the operation device in the touch screen, turn the knob to the touch screen side,
you can operate the device on the screen.
3、c is the auxiliary mechanism.

4、The operation of d is as follows: + + ，choose

lifting + left fixed AG to achieve the left roller fixed side oil cylinder AG lifting,
others similarly.
5、e is the cone bending operation, click on the tilt, the following tilted screen appears,
select the tilt tip in this screen,
 Picture 3 Tilted Screen

1、 + ,move to the left, select A+ lifting to realize the drop end

side of the left roll A lift;

2、 + ,move to the right, select B+ lifting to achieve the drop end

side of right roll B lift;In this way, the height difference between the left and right
roll is formed. Close the tilt and operate A and B to rise and fall at the same time.
Ⅲ、Displacement screen (see picture 4)

Picture 4

1、The pulse equivalent of MM/PPR and the length coefficient are set, so that the distance
display value is the same as the actual extend value of the oil cylinder piston rod by
the tape measure tool.MM/PPR is usually 0.03,the length coefficient is 1.
2、Length compensation is mainly used to eliminate some structural errors in the process
of equipment processing.In general, there is no need to modify.
Ⅳ、Parameter screen (see picture 5)

Picture 5 Parameter screen

Other parameters setting screen.This parameter has been debugged before leaving the
factory and does not need to be changed.
1、Positive and negative drive interval: 0.1s,
2、Click interval: 0.1s.

3、AB synchronous error: 1mm, the deviation corresponds to ，

is the deviation between the fixed side and the drop end side during the roll movement.

When closing ，the deviation doesn’t work；when opening

，the deviation of the fixed side and drop end side of rolls A
and B should keep balance within the established range.

4、AB closed loop difference: 1mm,the deviation corresponds to ,is

the deviation between the fixed side and the drop end side after the roll movement

finished，when closing ，the deviation doesn’t work；when opening

,the deviation of the fixed side and drop end side of rolls A and
B should keep balance within the established range.
5、 AB closed loop time: 0.5s, refers to the time required for the compensation of
executive end and automatically cut off.
Note: the two buttons of synchronous comparison and end compensation can be opened at
the same time. The principle is that the error of synchronous comparison is set to 2mm,
the end compensation is set to 0.5-1mm, and the end compensation resection time is set
to 0.1-0.5s.Or only open a synchronous comparison button, synchronous comparison error
is set to 1mm;Or only open one end compensation button, the end compensation error is
set to 1mm, and the end compensation time is set to 0.5s.
6、Upper limit of side roll tilt: it is mainly the maximum rising value of side roll.
7、The maximum displacement of side roll: this parameter should raise the side roll close
to the upper roll and record the displacement.The factory value is usually set to 999mm.
8、Slow speed distance: the length of the slow speed is the working length of the slow
motor;
9、D synchronous error: 0.5mm
10、D closed loop difference: 0.5mm
11、D closed loop time: 0.5s
12、Lower roll limit when overturning: 20mm.When the drop end is overturning, lower roll
shall come down, less than 20mm.
13、Roller distance: the distance between the bottom edge of the upper roll and the top
edge of the lower roll.
14、Maximum displacement of the lower roll: the distance between the bottom edge of the
upper roll and the top edge of the lower roll.
Note: 13-14 parameter settings must be consistent.
 15、Space compensation of upper and lower rolls: 0mm
16、Overturning time: drop end needs time to overturn.
17、Manual overturn 0/ automatic overturn 1: at the end of the automatic rolling, you
can choose to manually or automatically overturn.
18、Pressure head delays time: the pressure head oil cylinder returns, after touching
the limit switch, then delays time.
19、Error of bottom support roller: 1mm
20、Support roller (1)/no support roller(0) : whether the lower roller has support roller.

Ⅴ、Automatic Screen (as shown in picture 6)

a
d

c b

Picture 6 Automatic Screen

1、Click on a，appear ，drop down ABD roll to the bottom and reset.
2、Click on b, then input plate thickness to protect the plate in case of the plate being
clamped and deformed.

3、Console panel, dial to auto ，click the start button on the touch
screen,then realize automatic rolling plate；

Material alignment key , this button is to manually confirm whether the plate
material is correct or not when feeding.After confirming the alignment of the sheet
material, click the button to confirm the alignment and the system continues to roll.

Stop key, finish rolling, you can click the stop key,

Pause button. When you need to pause, click this button.To continue rolling,
click the pause button again.

Note:Under the circumstances of the suspension , it can be manually operated in the state
of automatic state.

4、c shows the rise and fall of each cylinder.

5、d is the limit switch display.

Ⅵ、Circle 1 (see picture 7)

Before automatic rolling, the preparation work is as follows:
1、Confirm that the device is in the synchronous comparison state.
2、Confirm that the device is clamped.
Picture 7 Circle 1
 C3

C1 图C28

This screen is the parameters input interface for our company's unique 12-section
automatic rolling process.

L=3.14*(2R+T),L is the length of straight sheet；R refers to the inner radius;T refers
to the thickness; Unit: mm.

：The thickness of the rolled plate is set in mm.

：The inner radius of the rolled circle is set in mm.

：Z is used for plate width compensation, that is height compensation of side

roll. Unit:mm.

：L plate length compensation prevents the splint from falling off。Unit:

mm.

：Set the inner radius R and plate thickness T, click "calculate", and the
system will automatically calculate the value of each step required when rolling.

:Plate length

：rising height of low roller

 ：height of the side roller when rolling

Feeding is a positive number, returning is a negative number.

In step 0 of rolling circle, set the value XXX

manually.

When the equipment reaches this value, it is the center of roll A directly facing the
sheet metal.

In step 1 of rolling, set the value 999

manually.

When roller A rises to the set value, the upper and lower rollers rotate feeding (+).
At this time, feed the plate and align it with the reference level of roller A. After
visual alignment, click "confirm", and the upper and lower rollers will clamp the plate.

The second step of rolling, automatically

clamping, clamping height = distance between up and lower roller - plate thickness.

Note: 1. If the plate material is clamped too tightly, please increase the thickness
of the plate material by 0-1mm;

2. If the plate material is too loose, please reduce the thickness of the plate
material by 0-1mm;

Step 3 of the circle, set 5%

manually.

When the clamping is complete, roll A falls to balance with roll D so that the plate
can go in flat.When the equipment reaches this value,roll A and D are on the same
horizontal line.Rising value =5%* height Z of side roller.

The fourth step of rolling circle, manually

set the returning distance to -xxx [negative number].
Roll A in step 0,the distance between the inner section of the roll and the center line
of the upper and lower rolls;When the equipment reaches this value, the material is
returned to the center of roll D.(when the value of roll D is positive, it is the feeding
time that means the motor is positively rotating to feed the material, and when the value
of roll D is negative, it is the returning time that means the motor is negatively rotating
to return the material.)

Step 5 of rolling, set 65%

manually.

The pressure head of roll B is used to prepare to pre-bend the head end of the sheet
material, and the rising value=65%* the height Z of side roller, which is usually in
the range of 60%-80%.

Step 6 of rolling circle, set

100mm manually.

In the step 5,after the side roller of roll B rises, the upper and lower motors feed
material 100mm, an arc will appear on the head end of the plate C1.

Note: step 05-06 is used on the first pre-bending of the head end, 60-90% of the
pre-bending can be completed. At 14-15, the second pre-bending of the head end can be
completed.

Step 7 of rolling, set 5%

manually.

When the equipment reaches this value,roll B descends to balance with roll D,and the
roll B and the roll D are on the same level,rising value =5%* height Z of the side roller.

Step 8 of rolling, set 100%

manually.

Roll A rises to the height Z of side roller , unit %, rising value=100%* height Z of
side roller.

Step 9 of rolling is automatic

calculation.
When roller A rises to the calculated value, it begins to roll. At this time, the motor
is positively rotating to feed the material.

Note: 1. The starting length of the arc in the step 05-06 must be tangent to the position
of the side roller rising height Z (step 08) when rolling.

2. The length of step 06 is short, forming the back angle;if long, forming a dead bend.

Step 10 of rolling, set 101%

manually.

When the equipment completes the 9th step, that is, the feeding and rolling is completed,
the upper and lower rollers just clamp the end of the plate (edge), and roller A needs
to rise a little more in order to pre-bend the end.Rising value=101%* side roller height
Z, which is usually between 100% and 105%.

In the 11th step of the rolling

circle, manually set the returning length to -100mm.

Roll A rises to the calculated value,begin to return the material -100mm, pre-bend C3.

(when the value of roll D is positive, it is the feeding time that means the motor is
positively rotating to feed the material, and when the value of roll D is negative, it
is the returning time that means the motor is negatively rotating to return the material.)
Below is circle two

Step 12 of rolling, set 5%

manually.

Roll A drops to balance with roller D.When the equipment reaches this value, roller A
and roller D are on the same level, the rising value=5%* side roller’s height Z.

In step 13 of rolling, set 100%

manually.

Roll B rises to the height Z of side roller , unit %, rising value=100%* height Z of
side roller.

Step 14 of rolling is automatic

calculation.

When roller B rises to the calculated value Z, it starts to roll. At this point, the
motor negatively rotates to return the material.
 At step 15 of rolling, set 101%
manually.

When the equipment completes the 14th step, that is, material returning and plate rolling
is completed, the upper and lower rollers just clamp the end of the plate (edge), and
roller B needs to rise a little more in order to pre-bend the head end C1.Rising
value=101%* side roll’s height Z, which is usually between 100% and 105%.

Step 16 of circle rolling, set

100mm manually.

When the side roller B in the 15th step rises, the upper and lower motors feed the material
100mm, and the first end of the plate C1 will have an arc [100%].

Ⅷ、Storage Screen (see picture 9)

命名 name

图9
1、Save operation:

Firstly, click save no. ， input 0-99,

then click technology ，name.

Lastly,click save ，complete save program

2、Download operation:

Firstly, click save no. ， input 0-99，then

click download

，完成调用程序 .
Ⅸ、Irregularity (picture 9)

Picture 9
1、Roll A,B,D
0.00 indicates that the current step of the equipment is the same as the previous step, and the
roller is not moving；
If the roll is selected to return to the zero position, set the corresponding roll’s parameter to 2；
2、Roll R
0.00 means not move, negative number means to return the material, positive number means
to feed the material.
A total of 80 actions to complete the product, discretionarily setting.

3、 ：Complete jumps of any steps.

4、 ：Click the insert step to bring up the screen ，

enter 4, and a set of data will be inserted between 3 and 4.

5 、 ： Click the delete step and the screen appears

，enter 4, and a set of data will be deleted before entering 4.

6、 ：Irregularity are all set to 0.

Ⅹ、Data Monitoring (see picture 10)

 Picture 10

Picture 10 shows the completed data by monitoring irregularity.

Ⅺ、Detailed parameter of D roller(see picture 11)

Picture 11
1、Steps 0-4 are consistent with the setting of circle 1 and circle 2 to complete the
material alignment process.
2、R1 sets the inside radius of the arc，L1 sets the length of arc.The setting of R1-R13,
L1-L13 is the same as R1, L1.
3、The end pre-bending function is completed in steps 10-12, which is similar to the
end pre-bending of circle 1 and circle 2.