Equipment for working with metal workpieces is created in the pursuit of multifunctionality in terms of the integrated implementation of various operations on one bed. But practice shows that even combining the simplest tasks for one unit inevitably reduces the quality of work. Therefore, in parallel with the concept of multifunctionality, there is the principle of separation of tasks - it was just in the framework of this idea that electromechanical rollers were selected that perform a rather narrow range of working actions. As a rule, they are used to produce rolled and shaped products, but depending on the modification, expansion of operational capabilities may also be provided.
General information about rollers
Rollers, or milling machines, belong to the category of bending equipment. This is a wide segment in which various structures perform certain tasks of metal deformation. Specifically, the rollers carry out work operations with metal, sheets and rods. The basis of the machine is formed by a stable and reliable bed, on which long rollers are located - as a rule, 3 elements are used. Especially for servicing wire, pins and reinforcing products, some roll designs provide grooves of a certain size. The electromechanical rollers are driven by an engine that is connected to the network. The operator during the operation of the machine controls the functional organs with the help of handles.
The principle of operation of the equipment
Compared to other metalworking machines, the rollers have a fairly simple functional diagram. Actually, the simplicity of the design also made it easy to control the working bodies with which the machine is provided. Rollers located on the axis of the bed provide rolling stock, deforming it with certain parameters. The workpiece is received by two front rollers, which rotate towards each other, and a vacation with a radius adjustment is performed by the rear rolling element.
Again, the specific model of physical impact on the workpiece may vary depending on the characteristics of the working axis. This can be the processing of sheets, and work with rods that are placed in special channels. Also, throughout the entire working process, three-roll electromechanical rollers hold the workpiece due to the energy supplied from the electric motor or from the manual effort of the operator. The clamping method may vary depending on the modification of the machine.
Unit Specifications
Usually, the choice is made according to three main characteristics - the thickness and width of the sheet allowed for processing and the diameter of the rollers. As for the thickness of the sheet, it is determined by the type of drive mechanism and the type of material that is suitable for use in a particular model. Standard units, for example, handle 0.9 mm stainless steel, process copper at 1.8 mm, and polycarbonate panels can also be 3 mm thick. The width of the workpieces allowed for work on average varies from 600 to 1300 mm. This indicator directly depends on the design on which the electromechanical rollers are based, its dimensions and regulatory bodies. In turn, the diameter of the rollers determines the radius of the molding - in other words, the magnitude of the circular bending of the workpiece. It can be 75-120 mm.
Varieties of machine tools
To obtain more accurate and generally high-quality products, the roll design is also complicated in modern models. So, there are devices in which 6-7 rollers are already provided. In addition to folding, they also perform unwinding and leveling operations. A separate place in the segment is occupied by jewelry rollers, which are characterized by the presence of two rollers. Such models specialize in wire drawing, so they do not need additional rollers. By the way, the diameter of the rollers for jewelry models is 65-80 mm, and the rental speed is 3-4 m / min.
In a sense, the opposite of a jewelry machine is a combination unit. It is distinguished not only by its versatility in terms of performing various operations, but also by the complete automation of work processes. Thanks to the control panel with controllers, this type of bending roll does not require the operator to manually adjust the position of the rollers and fix the workpieces with clamps.
Manufacturers and prices
In the domestic market, rollers produced by METALMASTER, Stalex are well known. METALMASTER, in particular, offers the ESR 2025 model, which provides for the rental of rods of different diameters, manual and electromechanical control, as well as the basic set of three-roll tooling functions for working with sheet metal. As for the Stalex models, these are small in size and universal purpose rollers, the price of which at the initial level is 8-10 thousand rubles. The middle segment, regardless of the manufacturer, offers such equipment for 30-40 thousand, and combined industrial units can cost 200-250 thousand. These are already models with an electronic control system that can process workpieces with a wide range of size formats.
Where are electromechanical rollers used?
For the most part, such machines are equipped with production facilities. The very direction of enterprises may be different. The technology of rolling material deformation allows in the case of metal to obtain profile elements for building structures, air ducts, segments of mounting blocks, lining elements for cars and all kinds of mechanisms. Such equipment is also used in the domestic sphere. For example, jewelry rolls are quite suitable for a large farmer, summer resident or just an economic homeowner who needs to have a supply of wire with certain parameters for certain needs.
Conclusion
Obtaining a high-quality product with the help of rollers is possible only if the operating technique is observed. The nuances of handling specific models can be found in the attached instructions, but there are general rules that should be followed. For example, sheet bending rollers should be installed only on a flat and stable surface. It is advisable to prepare a special platform for the unit that minimizes vibration. In the future, work with the machine should be organized in conditions of sufficient illumination, the availability of consumables and lubricating fluids. Do not forget about safety. Machine tools do not provide for the batch placement of metal billets, require compliance with cleanliness on external surfaces and are allowed to work only in good condition.