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Anerka HR-4 2050-200 Hydraulic 4 Roll Plate Rolling Machine
2050 mm is the length of the bend, and the pre-bending capacities are 6 mm Ødx1,5 bend, 8 mm Ødx3, and the bend capacities are 10 mm dx5.
Anerka HR-4 2050-200 Hydraulic 4 Roll Plate Rolling Machine
Anerka HR-4 2050-200 Hydraulic 4 Roll Plate Rolling Machine
Description
Benefits Of 4-Roll Plate Rolling Machines
- Four roll plate rolls are more precise, productive, versatile, faster, safer and easier to operate than three roll machines. They are less dependent on operator competence. They are ideal for bending plates up to 6″ thick.
- The fastest and most accurate bends are made by four roll machines. The plate is held securely in place between the top and bottom rolls while the side rolls move vertically to create the bend.
- The bottom roll moves up to hold the plate edge securely against the top roll while the side roll is raised to form an accurate pre-bend, minimizing the flat zone on the plate edge. Pre-bending on a double pinch three roll machine requires that plates be tilted down as they are being fed. In contrast, plates are loaded horizontally at the feed level for pre-bending on a four roll machine, which allows the use of horizontal motorized roller tables to help feed the plate.
- Plate feeding can take place on either side of a four roll machine. If fed from only one side, they can even be placed up against a wall to save floor space.
- The side rolls are positioned to the right and left of the bottom roll and are on their own axes. The independent axis of each roll helps make a perfect bend. The “back” side roll (at the far side of the feeding point) also functions as a back gauge to square the plate for proper alignment (see figure 1). This eliminates the need for someone to assist the operator.
- The plate is kept square without slipping during both pre-bending and rolling because of the constant secure clamping of the top and bottom rolls.
- Four roll machines do not require the operator to remove, flip, and then try to square the plate a second time after pre-bending, as is the case with three roll IP machines. Keeping the material in the machine makes four rolls 50% more efficient than three roll IP machines, and allows a cylinder to be rolled to the required diameter immediately following pre-bending.
- Bending the back edge takes place after the cylinder is rolled, for a one direction, single pass operation.
- Cone rolling is easier on a four roll machine. The side rolls can be tilted to establish the cone angle and the bottom roll can also be tilted to clamp and drive the plate.
- Four roll machines are the only type of plate rolls that can effectively make use of NC and CNC controls because of the constant clamping and driving of the material during all steps of rolling. Bending difficult shapes like polycentric or elliptic work pieces can be easily done with CNC four roll machines.
Engineering And Production Advantage
- The mechanical and hydraulic systems on HR-4 machines are designed by experienced ANERKA engineers. These engineers design the machines utilizing parametric 3D CAD technology as well as implementation of static and mechanism analysis. All mechanical, hydraulic, and electronic systems are designed and tested by ANERKA electrical and mechanical engineers. Only following lengthy tests and evaluations are the machines authorized to be manufactured in serial production.
Stable and Robust Machine Body
- The mechanical and hydraulic systems on HR-4 machines are designed by experienced ANERKA engineers. These engineers design the machines utilizing parametric 3D CAD technology as well as implementation of static and mechanism analysis. All mechanical, hydraulic, and electronic systems are designed and tested by ANERKA electrical and mechanical engineers. Only following lengthy tests and evaluations are the machines authorized to be manufactured in serial production.
Strengthen Guiding Systems
- Rolls are guided with spherical roller bearings and bronze beds. The guiding system requires less lubrication and keeps it precision in long term.
Rolls
- Rolls and their positions are selected after long term engineering, tests and evaluation periods. Side rolls are guided by linear beds which allows them to act as 2 independent axes moving on rectilinear line. System allows to bend minimum work piece diameter as 1.5 times of top roll diameter dependent to the capacity of the machine. Side rolls are approaches to the top roll on rectilinear movement which allows to get perfect prebendings as well as spring back minimization.
Durable Rolls and Crowning System
- The most important element of a plate roll bending machines are the rolls itself. Weak rolls in the market are deformed during the bending and minimum workpiece diameter reaches to 5 times of top roll diameter. Highly durable carbon steel (CK50) rolls are machined by CNC Lathes with high precision without creating notch effect. Working surfaces of the rolls are induction hardened to HRC 56±4 and hardness tests are done from different points.1,2 times diameters are acquired easily. Rolls are machined as crowning shape to compensate the deflections on the rolls during the bending. Special crowning for different material can be applied free of charge.
Precise Roll Positioning System
- Lower and side rolls are driven by 6 different strong hydraulic cylinders. Synchronization between the rolls are acquired by linear encoder and PLC’s responds within milliseconds. Thanks to high precision hydraulic valves. The bottom roll pressure manually adjusts to hold different thickness of material without deformation.
Hydraulic and Electrical System
- Machine movements are triggered by hydraulic components. The precision on all axes are acquired by world leaders. Duplomatic (Made In Italy) valves’ high speed response ability. And pressure safety valves used against peak pressures and overload, provides protection for motors and other components. Electrical system designed compatible with CE safety regulations.The system consists of well known electrical components such as Siemens, Schneider, Opkon. The system is protected by current overloadings for its components’, powersupplies, electronics and motors. PLC Unit used from Panasonic. NC, CNC Control Unit used from world leader Esautomotion (Made In Italy).
PLC Control System (Standard)
- PLC control system ensures the machine’s bottom and side rollers’ synchronous operation. This process is provided via the PLC with 6-axis control and touch screen operator panel. In addition, prior experience, the circular bending with the facility for bending up to 5 steps of the program, is ease of use and saves time.
ANERKA HR-4 PLC PLC Control Unit
- Dedicated scratch-proof, oil-proof, acid-resistant sealed touch panel
PLC
- Panasonic 32 I/O
Memory
- 5 Mbyte
Display
- Monochrome LCD 3” ekran
Resolution
- 128 (W) x 64 (H)
- 3 colors led backlight (green,red, orange)
Communication port – 1 RS232C Seri Port
Température – 20 / 60°C
Software
- Manual working mod,
- Standard 6 axies (X1,X2,Y1,Y2,P,P1)
- 3 colors display for machine situation
- Conic and parallelism control
- 5 set point programing
- Contrast adjusting
- Turkish,English, German, French, Spanish, Polish, Hungarian, Croation languages.
- Alarm list
NC Control System (Optional)
- NC control system, in addition to the PLC control system, has the property to work manual, teach-in and automatic modes of operation. In manual mode, the use of all functions are provided by the operator. In teaching mode for the operator to twist all the steps are recorded respectively. In automatic mode all recorded movements are repeated, respectively by the machine. Thanks to the software we developed, the NC unit also calculates the theoretical bending steps one by one. The operator can achieve perfect bend only by changing the pre-bend and rolling values that calculated by the software. NC control system has the capacity to save 5000 programs consisting of Max 200-steps.
NC Unit (S630) PLC
- Esautomotion / Italy
CPU
- VIA Eden® X1 1.06GHz
Memory
- 1GByte DRAM for CPU
- 128MByte Solid State Disk
Display
- Color TFT-LCD 10” WVGA
- Integrated VIA Chrome®9 HD DX9 Graphic Cont
Resolution – (1024×600, (R.G.B) Communication ports
- Ethernet Port
- 1 CAN interface
- 2 RS232C Serial Port
- 2 USB Port, 1 VGA Out
- Fiberoptic communication lines
Software
- Manual, teach-in and automatic working modes
- Standard 7 axes (X1,X2,Y1,Y2,P,P1,Z)
- Conic and parallelism control
- Adjustable speeds
- 200 step, 5000 program memory
- User friendly program editor
- USB port for programs backup
- Part pcs. programing
- Working hours counter
- mm / inch system
- Automatic turn off programing
- English, German, French, Spanish, İtalian, Russian, Polish, languages
- Alarm list
CNC Unit (Optional)
- The CNC unit, with its graphical control system allows the bending to be done step by step or by automatically calculating the bending steps. Due to changes in the structure of the material, corrections must be entered for pre-bending and bending steps after the first bended plate to get the desired bending form. Correction coefficients can be recorded to software for using them in similar characteristic material bending operations. With the CNC control you can easily bend parts into shapes such as: cylindrical, polycentric, elliptical, oval, parallel side, rectangular, and arc. CNC unit has interpolation capability due to proportional valves. The CNC unit can store more than 2,000,000 programs. The easy to use editor page also allows for simple editing of any saved programs. The unit also comes with a USB port allowing for easy up or downloading of your programs. You can also connect the control directly with your computer using an Ethernet cable. This also allows our service team to remote in if diagnosis is ever necessary. This also allows our service team to remotely access the machine if diagnosis is ever necessary. Lubrication system (offered as an option) operating times can be set at the control unit. Plate feeder, vertical and side supports (offered as an option) can be included as NC functions (teachable) into control unit. So supports can be programmed in teach-in mode and provided automatically during bending.
CNC Unit (S840) Hardware specifications
- Standard 7 axes (X1,X2,Y1,Y2,P1,P2,Z)
- Standard 32 inputs and 32 outputs
- 24Vdc 100W max power supply
- 15” TFT XGA color touch display with antiglare screen
- Ergonomic aluminum housing, with a panel suitable for machine operator
- Dedicated scratchproof, oil-proof IP65 keyboard with 28 keys
- 2.5” Hard disk drive 20GBytes or more
- Hand wheel for adjustable turning speed
- Industrial keyboard (PS2 standard connectors)
Technology
- CPU PC: Intel Atom N270 1,6Ghz with 1Gb of RAM
- CPU CNC: AMD Geode ETX-LX800 500 Mhz, with 128Mb of Ram
Communication ports
- 1 serial ports RS-232, 3 USB ports,2 Ethernet port on the PC
- 2 serial ports RS-232, 2 USB, 1 Ethernet port, 1 Can Open Port on CNC
- Fiber optic interface
- Local area network
User memory
- Hard disk for more than 2.000.000 part programs,
Software specifications
- Windows® 10 Embedded operating system
- Manual, teach-in and automatic working modes
- Conic and parallelism control
- Interactive 2D graphic editor for work-pieces and tools data entry
- 2D graphic display of machine rolls
- 2D automatic identification of the best bending sequence ,
- Programming of the axes positions in tabular mode with automatic syntactical checks
- Automatic calculation of the X,R,P and Z axes positions for cylindrical, polycentric, oval, oval parallel sides, rectangular, arc bending shapes
- Material database of common steel plates, X-Z / Y-Z axes interpolation capability
- Bending and working hours counter
- Metric and imperial measurements
- Off-line programming
- English, German, French, Spanish, Italian, Russian, Polish, languages
- Alarm messages
- CNC Software
Conical Bending System
- By strong body and angular bottom and side rolls, wide angle & small diameter conical parts are easily bent. While machines in the market is bending conical bendings of 3 times of top roll, ANERKA HR-4machines can bend conical bending of 1.5 times easily.
Optional Side, Vertical or Special Sheet Support System
- Optional hydraulic side or vertical supports the sheet’s stretch and prevent deterioration of the bending form in big shaped bendings. Moveable gauges with hydraulic double cylinders are produced from Gr50 steel construction. It can produced according to different tonnage and height. Bending Capacity and Calculation. Our machine capacities are defined for 36 KSI yield point sheets. For different length and thick sheets you can use ANERKA Bending Capacity Chart.
Bending Capacity and Calculation
- Our machine capacities are defined for 36 KSI yield point sheets. For different length and thick sheets you can use ANERKA Bending Capacity Chart.
Specification
| Model | HR-4 2050-200 |
| Number of rolls | 4 pcs. |
| Bending Length | 2050 mm |
| Pre-bending capacity Ødx1,5 | 6 mm |
| Bending capacity Ødx3 | 8 mm |
| Bending capacity Ødx5 | 10 mm |
| Top roll diameter | 200 mm |
| Bottom roll diameter | 200 mm |
| Side rolls diameter | 190 mm |
| Motor power | 7.5 Kw |
| Max. Pass Through | 13 mm |
| Power supply | 400V / 3 Phase / 50 Hz (Or other) |
| Bending speed | 4.4 m/min |
| Oil Tank Capacity | 160 L |
| Feeding rolls | 2 Planetary gear box and hydraulic motor |
| Rolls housing | All rolls housing spherical roller bearings and bronze bushings |
| Rolls material | High tensile carbon steel CK50 |
| Rolls hardening | Induction hardened HRc 56±4 |
| Rolls positioning | One speed electronic synchronous (Proportional Speed on NC-CNC) |
| Rolls calibrationing | Manual (Automatic on NC-CNC) |
| Pinching | Adjustable hydraulic pressure |
| Control unit | Standard PLC Optional NC or CNC |
| Conical bending | Manual bending with conical bending device |
| Lubrication | Manual or Automatic |
| Length | 3830 mm |
| Width | 1160 mm |
| Height | 1180 mm |
| Weight approx. (Basic Machine) | ~4340 Kg |
STANDARD
- Planetary type side roll movement.
- PLC Electronic balancing system
- Cone bending
- Induction hardened rolls (HRc 56±4)
- Polished rolls
- Single speed control of all axis
- Dual speed control of all axis (NC machines)
- Variable speed control of all axis (CNC machines)
- Machine body constructed of stress-relieved
- Highly durable carbon steel rolls machined by CNC Lathes with optimal crown(special crown upon request)
- Rolls seated in spherical bearings and bronzebushings
- Hydraulic bracket (drop end) with easy pull outsystem
- Top and bottom rolls driven with hydraulic motorand planetary gear box
- Automatic rolls peripheral speed compensation(optimum distribution of torque)
- Adjustable hydraulic pressure on bottom roll(crowning compensation)
- Emergency stop wire around the machine
- Electrical and hydraulic protection against overloads
- World standard electrical and hydraulic components
- Mobile control panel
- Manual lubrication
- Welding possibility on the machine
OPTIONAL
- NC Unit (Simple CNC)
- CNC Control Unit with color graphical control
- AISI 4140 High strength alloy steel rolls
- Four rolls drive
- Wired or wireless remote control
- Oil cooler
- Oil heater
- Side support system (both sides)
- Vertical hydraulic overhead support system2, 4 TON (2m – 3m – 4m diameters)
- Preparation for side or vertical support system
- NC inclusion for vertical support control(Available on CNC control)
- NC inclusion for side support control(Available on CNC control)
- Plate alignment unit
- Automation system
- Changeable top roll for smaller diameter
- Special roll crowning
- Special plate support systems
- Automatic central lubrication
- Material feeding table (Idle or motorized)
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Frequently Asked Questions
Should I purchase industrial machinery from a tool shop or reseller, or from an industrial machinery specialist?
Tool shops and general resellers may offer a wide product range, but often lack the specialised knowledge to properly assess applications or provide ongoing technical support. An industrial machinery specialist ensures the right machine is selected and fully supported long after purchase. In most cases, buying directly from the importer or specialist also results in a lower purchase cost, as additional reseller margins are not added.
What after-sales support and warranty do you provide?
Industry leading after-sales support, Australia-wide.
Backed by over 30 years of industry experience, more than two decades in business, and a long history of satisfied customers Australia-wide, Capital Machinery Sales provides after-sales support you can count on, long after your machine is delivered, backed by our dedicated support team.
- Application support: Whether your requirements are straightforward or highly specific, we work with you to ensure your machine is set up and performing for your exact application, and we are here to help as your needs evolve.
- Pre-dispatch testing: Every machine is fully checked and commissioned before it leaves us. It's a step that saves our customers countless issues down the track and sets your machine up for maximum uptime.
- Warranty: We don't just pass on the manufacturer's warranty. We offer our own comprehensive warranty that goes further, giving you greater coverage and peace of mind, with extended warranty options also available.
- Spare parts: Downtime costs you money, so minimising it is our priority. We keep a wide range of parts and consumables in stock, and if we don't have it on the shelf, we will track it down and get it to you as fast as possible.
- Remote support: Fast help via phone, email, or live video, with no site visit needed in most cases. We pride ourselves on some of the fastest response times in the industry, because we know that when you need help, you need it now.
- On-site service: Our engineers travel Australia-wide, with trusted contractors covering remote areas.
- In-house repairs: Send your machine back to us for expert servicing and overhaul.
How quickly will I receive my machine?
Often, we can ship the same day if required, depending on stock availability, the time your order is placed and the available shipping options.
Specification
Additional information
| Weight | 4350 kg |
|---|---|
| Dimensions | 393 × 126 × 128 cm |
| Kilowatt (kW) |
