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Plate Rolls Plate Bending Roll

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Product Description

Plate Rolls Plate Bending Roll up to 24 meters long and 10 meter OD and 200mm wall thickness

 

We have vast experience and market knowledge in supplying metal fabricating machinery to the structural steel and metal fabricating industries. Our corporate philosophy is creative and customer oriented. Our metal fabrication equipment is constantly evolving to reflect industry improvements and changing specifications and standards.

Our customer base is as diverse as our product lines. We service small ornamental iron and fabricating shops, mid-size manufacturers and large construction companies.

We offer the finest in hydraulic press brakes, plate shears, plate rolls, pinch rolls, plate bending machines, tube benders and several other types of precision metal fabricating machinery to meet all your needs.

Each Heller machine or part features the same outstanding quality that has become a Heller tradition. This combined sense of quality and integrity has made E.G. Heller's Son the industry leader in the field of metal fabrication equipment

Plate Roll Features

Pre-bending to the full rated capacity plate is accomplished with sufficient power in each side roll hydraulic cylinder. Many competitors are not capable of pre-bending to their maximum rated rolling capacity.

Rolls are easily adjusted on either end with Bertsch's unique electronic leveling system. Because most competitors allow adjustment on one end only, roll corrections are more difficult.

Spherical roller bearings increase drive's efficiency by reducing friction.

Operator controls are located on moveable pendant or console for ease of use.

Reduce potential leaks by eliminating connections and utilizing hard tubing throughout the machine, limiting the use of hoses only to areas requiring a flexible connection. Most competitors use hose connections exclusively, creating the potential for more leaks.

Variable speed differential achieved by the Independently Driven Top and Bottom Rolls, allowing them to seek their own speed when driving on the inner and outer radius. Some competitors offer inferior gear-to-gear or chain drive systems, limiting them to fixed speed differentials.

Four digital readouts, one for each side roll and two for pinch roll.

Pressure gauges monitor pinch pressure on both ends of the machine to monitor part squareness.

Hydraulic cylinder actuates the automatic self-locking hinge.

Customized crowned roll forgings adaptable to your specific rolling needs.

Operator safety ensured by electrical disconnect with lock-out feature, e-stop button located on control, and a trip switch located along both sides of the machine.

 

Optional Equipment and Enhancements

Overhead & Side Supports

Recommended when rolling larger diameters. Hydraulically adjustable and used to maintain cylinder shape during rolling.

Cone Rolling Attachment

The attachment is a removable snubber device, designed to retard the small end of the cone, allowing the large end to travel at a greater surface speed.

Alloy Hardened Rolls

Recommended when forming cones or when rolling hard materials that may leave permanent scarring in the roll surface.

Material Feed Systems

Custom designed for rolling application to reduce labor.

Plate Travel Monitor

Linear encoder measures plate travel, as a digital readout indicates plate location. Used when rolling parts requiring a flat prior to a radius.

Electronic Speed Control

Infinitely variable roll rotation speed provided directly from operations console.

Polished & Ground Rolls

For applications where surface is critical and minimal defects are allowed.

Custom Rolls

Custom designs to fit every rolling need — from rolling corrugated material to automated cells.

Control Options

Bertsch offers a range of control units—from manual/digital readout consoles to an NC Control console.

Bertsch NC Control

  • 15" color touch screen display
  • Network connectivity
  • Proportional control of rotation and all roll movements
  • Moveable console
  • Designed, developed and supported by the MegaFab engineering and service group
  • Programs can be created by editing individual blocks or by inserting actual roll positions by using the teach functionality as you roll.
  • A blended radius can be programmed by programming two axes in one block.
  • A comments section is displayed so that the operator can make notes about the job to help verify the program at a later date.
  • Remote service and diagnostics available via network connection
  • Virtually unlimited job storage via internal memory, usb or network connection

Note: The NC Control is designed to manage the machines axes.  How material reacts to these positions can vary greatly with changes in the materials dimensions and mechanical properties. Therefore, modifications to program positions are often required to adjust for these variables.

 

Plate Roll Specifications

Standard Rolls
5 Times Top Roll Diameter
Minimum Diameters
(at Maximum Width)
Model
Nominal
Thickness
Width
Top Roll
Diameter
Pre-Bend
Capacity
(Thick./Length)
Diameter
Max. Thick.
at 100% Width
Max. Thick.
at 70% Width
Max. Thick.
at 30% Width
Thickness
Diameter
Single Pass
Thickness
Diameter
Multi-Pass
25-08
0.250
96
9.0
.250 / 96
45.0
0.295
0.352
.538
.0188
11.0
0.250
17.5
25-10
0.250
120
9.0
.250 / 120
45.0
0.304
0.364
.556
0.203
11.0
0.266
17.5
25-12
0.250
144
10.5
.250 / 144
52.5
0.326
0.389
.595
0.219
12.7
0.281
19.0
37-08
0.375
96
10.5
.375 / 96
52.5
0.437
0.522
.798
0.281
12.4
0.375
19.0
37-10
0.375
120
10.5
.375 / 120
52.5
0.438
0.523
.799
0.281
12.4
0.375
19.0
37-12
0.375
144
12.0
.375 / 144
60.0
0.448
0.535
.818
0.297
14.2
0.375
20.5
50-08
0.500
96
12.0
.500 / 96
60.0
0.579
0.692
1.056
0.375
13.9
0.500
20.5
50-10
0.500
120
12.0
.500 / 120
60.0
0.577
0.689
1.053
0.375
13.9
0.500
20.5
50-12
0.500
144
14.0
.500 / 144
70.0
0.631
0.754
1.152
0.406
16.1
0.531
22.5
75-08
0.750
96
15.0
.750 / 96
75.0
0.901
1.077
1.645
0.594
16.9
0.781
23.5
75-10
0.750
120
15.0
.750 / 120
75.0
0.856
1.024
1.563
0.563
16.9
0.750
23.5
75-12
0.750
144
16.0
.750 / 144
80.0
0.883
1.055
1.611
0.578
18.0
0.766
24.5
100-08
1.000
96
17.0
1.000 / 96
85.0
1.152
1.377
2.104
0.750
18.9
1.000
24.5
100-10
1.000
120
17.0
1.000 / 120
85.0
1.150
1.374
2.099
0.750
18.9
1.000
25.5

All numbers in inches.

Note: ASTM A36 steel has a minimum Yield Strength of 36,000 psi. Above values are calculated using a Yield Strength of 45,000 psi.

pdf of Standard Rolls chart

Large Custom Rolls
5 Times Top Roll Diameter
Minimum Diameters
(at Maximum Width)
Model
Nominal
Thickness
Width
Top Roll
Diameter
Pre-Bend
Capacity
(Thick./Length)
Diameter
Max. Thick.
at 100% Width
Max. Thick.
at 70% Width
Max. Thick.
at 30% Width
Thickness
Diameter
Single Pass
Thickness
Diameter
Multi-Pass
#18
1.250
120
20.0
1.25 / 120
100.0
1.500
1.790
2.730
0.984
21.9
1.281
28.5
#20
1.500
120
22.0
1.50 / 120
110.0
1.760
2.110
3.220
1.156
24.0
1.500
30.5
#22
1.750
120
22.0
1.75 / 120
110.0
2.010
2.400
3.660
1.250
23.9
1.625
31.0
#24
2.000
120
25.0
2.00 / 120
125.0
2.190
2.620
4.010
1.453
27.0
1.906
36.3
#30
2.500
120
29.0
2.25 / 120
145.0
2.610
3.120
4.770
1.906
31.0
2.531
48.1
#32
3.000
120
31.0
2.50 / 120
155.0
3.030
3.620
5.530
2.266
33.0
3.000
57.1
#34
3.500
120
35.0
3.50 / 120
175.0
3.980
4.760
6.000
2.609
37.1
3.340
63.7
#36
3.750
120
38.0
3.83 / 120
190.0
4.410
5.270
6.000
3.031
40.1
3.859
73.5
#38
4.000
120
36.0
4.00 / 120
180.0
4.770
5.700
6.000
3.125
38.7
4.000
76.2
#40
4.500
120
40.0
4.50 / 120
200.0
5.400
6.450
6.000
3.531
43.8
4.448
85.5
#44
6.000
120
48.0
Consult Factory
Consult Factory
Consult Factory

Models shown are nominal capacities. Actual sizes and capacities vary based on application needs.

All numbers in inches.

Note: ASTM A36 steel has a minimum Yield Strength of 36,000 psi. Above values are calculated using a Yield Strength of 45,000 psi.

Rectilinear Guides (Bertsch Design)

Built for rolling heavy plate

Concept

The Rectilinear Guide concept consists of forming rolls that are guided in place by a machined surface, and bearing blocks mounted directly above the hydraulic cylinder. The position of the rolls is controlled by the hydraulic cylinder with no additional moving parts.

Advantages

Bertsch's Rectilinear Guide system transmits the forming roll forces directly to the hydraulic cylinder, into the machine frame, and into the foundation. There are no load-bearing wear points or torsional stresses affecting roll parallelism and accuracy. This leads to a long service life, consistent parts, and low maintenance. The centerline of the forming roll is close to that of the pinch roll. This allows the flat areas associated with pre-bending to be small and consistent. In addition, Bertsch sizes the direct-acting hydraulic cylinders to pre-bend to the maximum rolling capacity of each machine.

Each side of every forming roll is individually controlled, allowing fine roll adjustments, making cone rolling easy to set up. There are no torque tube stresses to account for.

Disadvantages

Rectilinear Guides are more expensive to produce because they require additional machining, and the hydraulic cylinders have a larger diameter.

 

Planetary Swing Guides (Competitor's Design)

Inexpensive, but less robust solution

Concept

The Planetary Swing Guide concept consists of the forming rolls mounted to a lever arm. The hydraulic cylinders are mounted so that a mechanical advantage is formed allowing use of a smaller diameter, and less expensive cylinder. The rolls move along an arc, and are cam guided. A torque tube is mounted between the hinge end and gear end of the machine, and attached to the levers in order to maintain parallelism of the rolls.

Advantages

This concept requires smaller cylinders and less machining than the rectilinear guides, and therefore costs less.

Disadvantages

  1. Each side of every forming roll requires a minimum of four pivot points (see diagram). These pivot points consist of a pin and a bearing. The entire bending load of the machine is translated through these pins and bearings resulting in faster wear. This wear creates loss of parallelism and therefore difficulty in maintaining consistency from part to part.

  2. The centerline of the pinch and forming rolls are larger than on rectilinear machines. As a result, the flat associated with pre-bending is larger, creating more part inconsistencies.

  3. The amount of mechanical advantage becomes limited as the forming cylinder rises for pre-bending. The cylinders are typically not sized to handle this additional force, therefore the machines are not capable of pre-bending the material to its nominal rolling capacity.

  4. The torque tube is sized in order to allow some twist for the purpose of cone rolling. The torque tube is not capable of keeping the rolls parallel.

  5. The torque tube creates twisting stresses in the lever and machine frame.

Bertsch Large Custom Rolls

Power and Precision up to 14" Thick

Custom Bertsch rolls are built to handle the most severe applications.

Rectilinear Guides and Electronic Roll Leveling are the foundations of Bertsch's reputation for long-lasting heavy-duty rolls.

Bertsch rolls are capable of rolling to 1.1 times top roll diameter. All Bertsch rolls can pre-bend at rated rolling capacity.

 

Bertsch Bending Roll
Applications

Bertsch bending rolls are ideal
for producing rolled parts
for a wide range of industries.

Fabricating equipment

Pressure vessels

Concrete mixers

Mining equipment

Heat exchangers

Boilers

Pipelines

Drilling rigs

Electric motors

Heavy turbines

Water treatment equipment

Chimney tubes

Air compressors

Snow plows

Heavy equipment loaders

Excavating equipment

Water towers

Wind towers

Road compacting equipment

Storage tanks

Fuel tanks

Nuclear reactors

Grain & Water storage systems
Water heaters

Autoclaves

Food & beverage processing equipment

Coolers

Structural steel manufacturing

Filters

 

 

 

3 & 4-roll plate bending rolls

 

 

     

VBH

4-roll fully hydraulic

 

●Plate thickness from 3 up to 280 mm

●Rolls length from 500 up to 8.000 mm

●Rolls diameter from 160 up to 1.600 mm

 

 

 

 

TBH

3-roll double pinch pyramid type

 

●Plate thickness from 3 up to 150 mm

●Rolls length from 500 up to 8.000 mm

●Rolls diameter from 160 up to 1.100 mm

 

 

 

 

 

 

PCO

3-roll with all three adjustable rolls

 

 

●Plate thickness from 3 up to 300 mm

●Rolls length from 500 up to 8.000 mm

●Rolls diameter from 250 up to 1.700 mm

 

 

 

 

TAS

3-roll  asymmetric (single-pinch)

 

●Plate thickness from 1 up to 8 mm

●Rolls length from 500 up to 3.000 mm

●Rolls diameter from 110 up to 180 mm

 

 

 

 

HDC

3-roll for aircraft & shipbuilding industries

 

●Plate thickness from 1 up to 80 mm

●Rolls length from 1.500 up to 20.000 mm

 

 

 

Warranty Information

18 month

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