So you've decided to invest in a Marine plate Rolling machine for your shipyard. Great choice - Plate Rolling machines can help increase productivity and efficiency. But with so many options out there, how do you choose the right one for your needs? This guide will walk you through everything you need to know about Marine plate Rolling machines so you end up with a tool that suits your shop perfectly. We'll go over the different types of plate rollers, what kinds of materials they can handle, factors to consider like budget and capacity, and tips for getting the most out of your new equipment. By the end of this, you'll be Rolling out high-quality plates in no time. Ready to get started? Let's dive in.
The Specification Of Marine Plate Bending Machine
Model |
Full-load Min Radius |
Rows Of Back-up Roller |
Main Motor Power |
3R-2200Tx21000 |
R650mm |
8 |
75KWx2 |
3R-2200Tx18000 |
R650mm |
8 |
75KWx2 |
3R-2000Tx17000 |
R650mm |
6 |
75KWx2 |
3R-1500Tx13500 |
R600mm |
4(7) |
55KWx2 |
3R-1000Tx12500 |
R600mm |
5(6) |
30KWx2 |
What Is a Marine plate Rolling machine?
A Marine plate Rolling machine is a specialized piece of equipment used in shipbuilding and other heavy industries working with steel plates. Shipbuilders use these machines to bend and roll steel plates into rounded shapes to construct ship hulls and other structures.
What does a Marine plate Rolling machine do?
A Marine plate Rolling machine has three main parts:
Rollers: Two or more heavy rollers that apply pressure to bend the steel plate. The top roller is movable while the bottom rollers remain stationary.
Drive system: Powers the rotation and movement of the top roller. This is usually an electric motor and gearbox system.
Frame: Holds the rollers and drive system in place. The frame needs to be extremely rigid to handle the forces involved in bending steel plates.
The basic process of a Marine plate Rolling machine is:
A steel plate is loaded onto the bottom rollers. The leading edge of the plate is aligned to the correct bend radius using guide arms.
The top roller is lowered onto the plate and the drive system is engaged.
As the plate passes through the rollers, the bend radius is formed. The plate emerges with an arc shape.
The plate is removed and the process repeats. Multiple passes may be required to achieve the desired bend radius and arc shape.
Additional forming operations like trimming, welding, and grinding are often needed to finish the workpiece.
Marine plate Rolling machines can produce single curvature bends, compound bends with varying radii, and complete circles. The size and thickness of plates that can be rolled depends on the capacity of the specific machine. Proper operation requires experience to achieve high quality, efficient results.
In summary, a Marine plate Rolling machine is a specialized tool that allows shipbuilders and steel fabricators to efficiently bend steel plates into the curved shapes needed for ship hulls, tanks, and other applications. With the right operator, it’s a vital piece of equipment for any major shipyard.
Key Features and Capabilities of Marine Plate Rolls
Key Features and Capabilities of Marine Plate Rolls
Marine plate Rolling machines, or plate rolls, are designed specifically for shipbuilding and heavy fabrication industries. They have several unique features that enable them to bend thick steel plates into cylindrical or conical shapes.
Powerful Drive System
Plate rolls require an extremely powerful drive system to provide enough torque to bend thick, high-strength steel plates. They are usually equipped with one or more electric motors that can generate 100 horsepower or more. Some larger models use hydraulic systems to power the drive rolls. This powerful drive system is one of the key features that distinguish plate rolls from typical sheet metal rolls.
Adjustable Tooling
The top and bottom rolls of a plate roll must be adjustable to accommodate plates of different thicknesses. The gap between the rolls needs to be increased or decreased depending on the plate thickness. Plate rolls typically have hydraulic cylinders or screws that are used to raise and lower the rolls. Some models also allow for camber adjustment to put a bend in the plate.
Removable Entry and Exit Guides
Entry and exit guides help guide the plate into and out of the plate roll. On most plate rolls, these guides can be removed or retracted out of the way to allow for Rolling conical sections. The ability to remove the guides provides more flexibility and the option to roll tapered cylinders.
Powered Bed and Rollers
High-quality plate rolls have powered beds, with either hydraulic cylinders or electric drives, that help pull the plate through the machine at a consistent speed. Power-assisted bed rollers require less effort from the operator and help improve productivity and quality. The rolls themselves are also typically power-assisted for the same reasons.
Heavy-Duty Frame
To handle the forces required for Plate Rolling, a heavy-duty welded frame is required. Plate rolls need to weigh at least 10 to 30 tons to remain stable during operation. The frame also needs to have an open area between the top and bottom rolls to allow for Rolling conical and tapered sections.
A marine plate roll with these robust features can bend plates ranging from 1/4 inch up to 4 inches thick, at widths up to 30 feet. For shipbuilders, these machines are essential for efficiently fabricating hulls, decks, bulkheads, and other curved components.
Top Manufacturers of Plate Rolling Machines for Marine Applications
When it comes to Marine plate Rolling machines, a few manufacturers stand out for their high quality products and experience in the shipbuilding industry. These companies are leaders in designing and producing plate rolls, press brakes, and other metal fabrication equipment for marine applications.
Maxim Machine
Maxim Machine Company has over 60 years of experience providing heavy-duty plate rolls and press brakes to shipbuilders. Their marine plate rolls are built rugged to handle high-strength steel alloys used in ship hulls and decks. Maxim's 4-high plate rolls are a popular choice for Rolling thick plates. They offer a range of standard machine sizes as well as customized designs.
Sahinler Metal
Sahinler is a Turkish manufacturer that produces a variety of plate rolls, including 4-high and pinch roll models for marine applications. Their plate rolls are used by shipyards around the world to roll high-strength steel plates up to 12 inches thick and 30 feet wide. Sahinler focuses on robust, high-precision plate rolls that provide excellent material handling and uniform Plate Rolling.
Akyapak
Akyapak is another leading Turkish plate roll manufacturer with a strong presence in the shipbuilding industry. They produce a range of 4-high plate rolls, pinch roll plate bending machines, and press brakes for marine applications. Akyapak's plate rolls are capable of Rolling steel plates up to 100 mm thick and 12 m wide, ideal for fabricating large ship hull plates and sections. Their machines are used in shipyards throughout Europe, Asia, and the Middle East.
Durma
Durma is a global manufacturer of metal fabrication equipment, including plate rolls, press brakes, shears and more. They produce a range of standard and customized 4-high plate rolls for the shipbuilding industry. Durma's plate rolls are robust, high-quality machines capable of Rolling steel plates up to 200 mm thick and 12 m wide. With Durma, you get a reputable brand, innovative design, and worldwide customer support.
The major players in Marine plate Rolling machines each offer high-performance, heavy-duty equipment built to meet the demanding needs of shipbuilders. When selecting a plate roll, consider factors like maximum plate thickness and width, drive power, material handling abilities, and the overall robustness and precision of the machine. A reputable brand with a proven track record in the shipbuilding industry is also important.
How to Choose the Right Plate Rolling Machine for Your Shipyard
Choosing a Plate Rolling machine is an important decision that will impact your shipyard's productivity and efficiency for years to come. There are a few key factors to consider to ensure you select the right machine for your needs.
The first thing to determine is the thickness range of plates you need to roll. Plate Rolling machines typically handle a range from 1/4 inch to over 4 inches thick. Select a machine rated for the full range of plates you anticipate Rolling to allow for flexibility and future growth.
Next, consider the width capacity. Ship plates can be quite wide, up to 30 feet or more, so make sure the machine has enough power and a large enough throat opening to handle your widest plates. Wider machines may require larger foundations and more floor space, so factor that into your facility plans.
How quickly do you need to roll plates? Production speed can vary significantly based on the machine. Hydraulic machines are typically slower, while all-electric servo-hydraulic models can roll at up to 200 feet per minute. Choose a machine with enough speed to meet your output requirements.
Finally, look at the overall quality and durability of the machine. Plate Rolling machines need to handle immense forces and pressures, so a heavy-duty, robustly constructed machine is essential for shipyard use. Consider factors like the thickness of side frames, quality of components, and available warranties or service contracts to determine a machine’s durability.
By evaluating these key factors—plate thickness range, width capacity, production speed, and overall durability—you'll be able to choose a Plate Rolling machine perfect for your shipyard's needs. The right machine will allow you to roll plates more efficiently, cost-effectively and with higher quality results for years to come.
Maintenance Tips to Keep Your Marine Plate Roller in Top Shape
To keep your Marine plate Rolling machine in peak operating condition, follow these maintenance tips:
Perform routine inspections. Visually inspect your plate roller before and after each use to check for any visible signs of damage or wear and tear. Look for oil or hydraulic fluid leaks, loose or damaged rollers or bearings, and any dents or dings in the framework. Address any issues immediately to avoid costly repairs down the road.
Lubricate moving parts. The rollers, bearings, chains, and gears need to be properly lubricated to reduce friction and prevent overheating. Grease or oil these parts regularly according to the manufacturer's recommendations. Lack of lubrication is a leading cause of equipment failure.
Tighten loose parts. Double check that all fasteners like bolts, nuts, and screws are securely tightened. Loose parts can cause the plate roller to wobble, vibrate or make excessive noise during operation.
Change filters and fluids. Replace hydraulic fluid, oil, and air filters at the recommended intervals. Clogged or dirty filters reduce efficiency and can damage internal components.
Perform test runs. Run the plate roller through a few test cycles with no plate to ensure all parts are functioning properly before using it for an actual job. Listen for any strange noises and check that it is running smoothly at different speeds.
Clean the machine. Built-up dirt, grime, metal shavings and debris can damage your plate roller over time. Wipe down the entire machine after each use to remove any waste and prevent the buildup of corrosive materials. Pay extra attention to the rollers, chains and gears.
Consider professional servicing. For the best performance and longest lifespan of your marine plate roller, have it professionally serviced by a certified technician once a year or every 500 hours of operation, whichever comes first. They can fully inspect all parts and make any necessary repairs or adjustments to keep your machine Rolling like new.
Following a consistent maintenance schedule will help ensure your marine plate roller provides years of reliable service. Keeping it well-oiled, tight, clean and tuned-up is the key to minimizing downtime and maximizing your investment.
Conclusion
So there you have it, an overview of Marine plate Rolling machines and how they can benefit your shipbuilding operation. While these machines require a hefty upfront investment, the long term gains in productivity, quality, and cost-savings make them well worth the price of admission. If you're looking to scale up production, reduce waste, and build ships faster and better than ever before, Marine plate Rolling machines should be at the top of your wish list. The next time you're walking the yard floor of your shipbuilding facility, imagine how much more efficient and streamlined the operation could be with one of these technological marvels on site. The future of shipbuilding is automated, so why not start Rolling with the times?