A metal plate roll bending is a machine used to transform flat sheets into curved elements through a controlled plastic deformation process. The sheet metal advances between adjustable rollers (typically three), which progressively determine its curvature, allowing precise shapes such as cylinders, cones and curved profiles to be obtained.
Requirements:
Control of the position of the bending rolls
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Hydraulic circuit pressure measurement
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Monitoring the temperature of the hydraulic circuit oil
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Requirement:
Control of the position of the bending rolls
Precise control of the position of the rolls is essential to ensure the bending quality of the finished product. Even small deviations in height, parallelism, or centering can cause ovalization, unwanted taper, and reduce repeatability between parts.
Correct roll adjustment allows deformation forces to be distributed evenly, avoiding residual stresses and maintaining sheet thickness in critical areas. It also allows the process to be adapted to variations in material thickness, width, and hardness, ensuring dimensional uniformity and final product quality.
For the correct positioning of the rollers in plate roll bending, it is necessary to have position measurement systems capable of providing a continuous, reliable signal proportional to the actual movement of the mechanism. Two technologies are commonly used in these applications: magnetostrictive position sensors and potentiometric position sensors, both suitable for ensuring precise control of the roller position and stability of the calendering process.
The WPA series magnetostrictive linear position sensors offer high stability over time, no contact between the slider and the sensitive element, and therefore no mechanical wear. These characteristics make them particularly suitable for applications with repeated cycles, vibrations, and stresses typical of metalworking machinery.
The PC potentiometric linear position sensor, on the other hand, is a simple and effective solution, appreciated for its signal linearity, immediate response to movement, and ease of integration into machine control systems.
With the WPA and PC sensors, Gefran offers linear position sensors designed to ensure precision, reliability, and operational continuity in metal plate roll bending applications.
Requirement:
Hydraulic circuit pressure measurement
In metal plate roll bending, it is essential to know and control the force applied between the rollers and the material in order to maintain the curvature within a stable and repeatable process window. Accurate control ensures uniform curvature, consistency between production batches, and the ability to adapt to variations in sheet thickness, width, and strength, avoiding processing defects and overloads that could damage both the workpiece and the machine.
In this context, the pressure sensor provides a continuous and accurate measurement of the force applied, allowing you to control the bending process and ensure consistent quality of the final product.
Solution:
The KS series pressure sensors are the ideal solution for measuring pressure in hydraulic circuits that control the positioning of rollers in a metal plate roll bending. Thanks to advanced technology, a latest-generation steel membrane film sensing element, and a compact stainless steel design, these sensors offer maximum robustness and reliability.
Main features:
- SIL2 certification
- Measuring range from 4 bar to 1000 bar
- Available with analog output and IO-Link communication
With the KS series pressure sensors, Gefran offers solutions designed to ensure measurement accuracy, reliability, and operational continuity in the hydraulic systems of sheet metal calenders.
Requirement:
Monitoring the temperature of the hydraulic circuit oil
Monitoring the temperature of hydraulic oil is essential to prevent overheating, which can compromise performance and damage components.
At high temperatures, oil loses its lubricating properties, accelerating wear and failure. Maintaining the temperature within the optimal range, generally between 45°C and 50°C, ensures proper operation and long system life, while preserving operational efficiency and avoiding unnecessary maintenance.
Solution:
The TR1 resistance temperature sensor with welded connection (TR1C) is the ideal solution for monitoring hydraulic oil in tube bending machines, ensuring constant temperature control and preventing the risk of overheating.
Main features:
- Thermoresistance technology (Pt100 / Pt1000)
- High precision and stability over time
- Robust stainless steel housing
- Easy integration into hydraulic circuits
With the TR1 temperature sensor, Gefran offers a reliable solution for monitoring temperature in hydraulic circuits, helping to ensure operational stability and protection of machine components.
Operating principle:
This technology is widely used in the production of tanks, pipes, metal structures, and components for industrial machinery. Thanks to the accurate control of the position and pressure of the rollers, metal plate roll bending ensures uniform processing, consistent quality, and high repeatability even in the most demanding applications.
Requirements and technology:
A metal plate roll bending requires a control system capable of ensuring precision, uniformity and stability throughout the entire bending process. A key aspect is the accurate control of the position of the rollers, which is essential for maintaining a constant bending radius, preventing defects along the piece, and ensuring repeatability between production batches.
At the same time, reliable pressuremanagement in the hydraulic circuitis essential to achieve smooth, synchronized, and repetitive movements, even in the presence of variations in sheet thickness, width, or rigidity.
The latest generation of plate roll bending incorporate high-precision position sensors and pressure sensors, which allow continuous monitoring of critical parameters and help maintain the stability of the bending process, ensuring reliable, repeatable, and high-quality production .