In the metal processing industry, a plate rolling machine is a commonly used piece of equipment used to bend or curl metal sheets into desired shapes. However, to ensure production consistency and quality, plate rolling machines must undergo regular calibration. This guide will explain the importance of plate rolling machine calibration, the steps to do so, and the key factors to ensure consistent results.
Table of contents
I. What is plate rolling machine calibration?
II. Why is it necessary to calibrate the plate rolling machine?
III.Steps for calibrating the plate rolling machine
IV. Common problems and solutions for plate rolling machines
I. What is plate rolling machine calibration?
Plate rolling machine calibration is a critical process designed to adjust and verify the various components of the plate rolling machine to ensure its accuracy and consistency during the metal processing process. Specifically, this calibration work involves inspecting, adjusting and calibrating the various mechanical, electronic and hydraulic systems of the plate bending machine to ensure that they work as expected and meet specific technical specifications and safety standards.
During the calibration process of the plate rolling machine, the following aspects are usually involved:
Mechanical component adjustment:
This involves adjusting the position and spacing of the rollers to ensure that the sheet metal is bent correctly during the curling process. Additionally, it may involve calibrating the position and pressure of the press and side rollers to ensure that the sheet is properly supported and pressed.
Electronic system calibration:
Modern plate rolling machines are usually equipped with electronic control systems to monitor and adjust various parameters during the plate rolling process. During the calibration process, these electronic systems need to be inspected and calibrated to ensure their accuracy and reliability.
Hydraulic system adjustment:
The hydraulic system plays an important role in the operation of the plate rolling machine, controlling the movement of the rollers and the application of pressure. Calibrating a hydraulic system involves checking hydraulic pressure, flow, and leaks to ensure the system is working properly.
Safety function inspection:
In addition to the calibration of mechanical and electronic systems, the safety functions of the plate rolling machine, such as emergency stop buttons, safety shields, etc., also need to be checked to ensure the safety of operators and equipment.
II. Why is it necessary to calibrate the plate rolling machine?
The accuracy of the plate rolling machine directly affects the quality and precision of the final product. An uncalibrated plate bending machine can cause product size inconsistencies, shape deviations or production interruptions, impacting production efficiency and customer satisfaction. Here is a more detailed explanation:
Ensure product quality and accuracy:
The accuracy of the plate rolling machine directly affects the quality and accuracy of the final product. By regularly calibrating the plate rolling machine, you can ensure that the metal sheets produced have the correct size, shape and surface quality, thereby avoiding product defects caused by dimensional deviations or irregular shapes.
Ensure production consistency:
Calibrated plate rolling machines produce consistent processing results, whether in batches or single-piece production. This consistency is critical to meeting customer requirements, maintaining brand reputation, and increasing productivity.
Reduce scrap rates and costs:
An uncalibrated plate bending machine may cause product size inconsistencies or shape deviations, which in turn increases scrap rates and rework costs. By ensuring the accuracy and stability of your plate rolling machine, you can reduce scrap rates and reduce costs associated with substandard products.
Increased productivity:
Calibrated plate rolling machines are often able to operate at higher speeds and efficiency because they are able to perform machining tasks more accurately, reducing the need for interruptions and adjustments, thereby increasing productivity.
Comply with industry standards and regulatory requirements: Many industries have strict quality standards and regulatory requirements, requiring equipment in the production process to be regularly calibrated to ensure compliance. By adhering to these standards and regulations, you can avoid potential legal liability and industry penalties.
III.Steps for calibrating the plate rolling machine
Plate rolling machine calibration is a complex and important process that requires certain steps and operations. The following are detailed plate rolling machine calibration steps:
1. Preparation:
Before starting the calibration, preparations need to be made to ensure that the plate bending machine is in a suitable state for calibration. This includes:
Clean the machine surface: Remove dust, oil and other impurities from the machine surface to ensure accuracy during the calibration process.
Confirm that all components are in normal working order: Check individual components such as rollers, hydraulic systems, electronic controls, and safety devices to make sure they are not damaged or malfunctioning.
2. Calibration steps and operations:
After the preparation work is completed, specific calibration steps and operations can be started, including:
Adjust the roller position and spacing: Using special tools, adjust the roller position and spacing of the plate bending machine to ensure that it is suitable for the required processing tasks. This involves adjusting the position and gap of the upper and lower rollers to ensure that the sheet metal is bent correctly.
Correct axial, radial and flatness errors: Use measuring tools to check the axial, radial and flatness errors of the rollers and make corrections. This ensures the accuracy and stability of the roller during operation.
Adjust the position and pressure of the pressure roller and side roller: Adjust the position and pressure of the pressure roller and side roller to ensure that they can correctly support and press the metal sheet to avoid shape deviation and dimensional inconsistency.
Record calibration results: During the calibration process, record all adjustment parameters and results. These records serve as future references to help track and manage the performance and maintenance of the plate bending machine.
3. Tools and equipment used:
Calibrating a plate rolling machine requires the use of various tools and equipment. Commonly used ones include:
- Plate rolling machine calibration plate: used to check the flatness and axial error of the roller.
- Plate rolling machine calibration ruler: used to measure the radial error and gap of the roller shaft.
- Ruler and tape measure: Used to measure the size and shape of boards.
- Plate rolling machine calibration software: used to record and analyze data and results during the calibration process.
IV. Common problems and solutions for plate rolling machines
When calibrating a plate rolling machine, you may encounter various common problems, including but not limited to the following:
Roller position offset:
Problem description: The position of the roller does not match the required position, resulting in deviation of the metal sheet during the rolling process.
Solution: Use calibration tools and adjustment mechanisms to adjust the position of the roller so that it meets the requirements. It may be necessary to adjust various parts of the machine such as the upper, lower and side rollers.
Uneven spacing between rollers:
Problem description: The roller spacing of the plate rolling machine is uneven, causing the metal sheet to form irregular bends or curls during the rolling process.
Solution: Use a calibration tool to measure the spacing of the rollers, and adjust the position and gap of the rollers based on the measurement results to ensure that they remain uniform throughout the rolling process.
The hydraulic system pressure is unstable:
Problem description: The pressure of the hydraulic system of the plate rolling machine is unstable, resulting in uneven pressure application on the roller shaft, which affects the processing quality of the metal sheet.
Solution: Check various components of the hydraulic system, such as hydraulic pumps, oil pipes and valves, etc., to ensure that they are working properly. The hydraulic system may need to be cleaned, hydraulic oil replaced, or damaged parts repaired.
Electronic control system failure:
Problem description: The electronic control system of the plate rolling machine failed and could not accurately monitor and adjust the machine's operating parameters.
Solution: Check the connections and power supply to the electronic control system to make sure it is working properly. The electronic control system may need to be recalibrated or damaged parts replaced.
Safety device failure:
Problem description: The safety device of the plate rolling machine fails, which may cause injury to the operator or damage to the equipment.
Solution: Check safety devices, such as emergency stop buttons, safety shields and photoelectric sensors, to ensure they are working properly. If necessary, repair or replace damaged safety devices.
V.Conclusion
Plate bending machine calibration is critical to ensuring consistency and quality of production. Through regular calibration and maintenance, the accuracy and performance of the plate rolling machine can be maintained, improving production efficiency and product quality.
This guide provides information on how to calibrate a plate rolling machine. To learn more about plate rolling machines, click here. KRRASS will be at your service.
