Plate Rolling Machines
DAVI Plate Rolls portfolio includes 3 and 4 roll machines (both in horizontal and vertical configuration) with a thickness capacity up to 12″ and width up to 20 ft. These machines are suitable for any type of application. Special configuration such as Vertical Press Roll and Pre-Stressed Plate Roll are available upon request. DAVI standard solution includes digital Roll-by-Wire and Servo-Tronic® parallelism (patented), in order to grant the best result in terms of repeatability and accuracy. DAVI Plate Rolls can be equipped with the most user-friendly automation including DG-Gauge radius measurement control capable of supporting the operator on the control of the radius.
MAV (3-ROLL VARIABLE AXIS PLATE BENDING MACHINE)
A 3-roll variable-axis plate rolling machine operating principle is conceptually similar to that of a press-brake, with the top roll pressing the plate between the two side rolls. However, a 3-roll bending machine is much more flexible and accurate, being able to vary the inter-axis distance between the bottom rolls. In this regard, DAVI MAV allows for individual, horizontal movement of both side rolls and vertical movement of the top roll. Furthermore, each one of the 3 rolls features rotation drives and can be tilted in every direction for cone bending.
MCO (3-Roll Double Pinch Plate Bending Machine)
The most common design in the plate roll market, with a fixed top roll, the two side rolls swing up for pre-bending and rolling. Costing less than a four roll, the MCO three roll double pinch can roll plates from 15-20 mm (5/8 – 3/4 inch) thickness, up to 80-100 mm (3 – 4 Inch), or more, ideal for limited production volumes.”
NO REMOVAL OF PLATE
The MCO uses both side rolls to prepend the plate, called “double pinch” therefore both ends of the plate can be pre-bent without removing the material from the machine (impossible on any single initial pinch, asymmetric designed machine). As the side rolls raise and lower to pre-bend the two edges, the large free access allows to form high stock bar through the rolls, compared to other roll designs.
The MCO has three independently powered rolls, mounted directly to each roll shaft to offer the market’s most powerful torque transmission available. This ensures excellent plate feeding without the risk of plate slipping. Standard feature on other brands offer only the top roll OR only the two side rolls powered, making thin, narrow or large diameter cylinders hard to properly feed. Optional auxiliary motors can be offered on request, but these are small and without much power.
All three rolls are safely braked efficiently, automatically and hydraulically instead of using low efficiency, consumable brake linings common to other brands.
MCA (4-Roll Plate Bending Machine)
Innovative and exclusive in design, to roll plate up to 10-15 mm (1/2 inch) thick. Accurate, fast, easy and intuitive, it is the most high-tech plate roll for “light gauge” in the market.
ONE PHASE CYCLE
Unlike on a three roll plate rolling machine, there is no need to pre-bend the two edges of the plate first and then roll the cylinder. A cylinder can be rolled, including the pre-bending of both ends, feeding the plate forward through the rolls in a single motion. ”
The operator needs to only find the correct position of the side rolls to successfully roll the plate.
Different choices of CNC controls are available, from an entry-level, user-friendly CNC to roll parts in automatic mode or more powerful and advanced DAVI CNC controls in the industry which can be self-programmable reducing the need of the most experienced plate roll operator.
Unlike other brands using brake linings that wear out, Davi incorporates the safety of automatic and hydraulic assisted braking for both clamping rolls to ensure accurate plate feeding.
Plates are loaded horizontally to allow the use of an in-feed conveyor and automated loading and unloading systems. The CNC controlled plate roll then becomes an automated un-manned rolling center greatly reducing cycle times, ideal for high quantity production runs.
MCB (4-Roll Plate Bending Machine)
Whenever repeatability, productivity and ease of use are of essence, the 4-roll is the technology of choice. In a 4-roll machine, latest development of the rolling technology, the bottom roll clamps the plate guaranteeing a perfect control over its position throughout the whole forming process. The side rolls, actuated by the unique DAVI planetary guides technology, provide the necessary bending force achieving the tightest diameters per capacity on the market (1.1 of the top-roll) obtaining the highest accuracy thanks to the perfect parallelism offered by the patented Servo-Tronic© system. Compared to other technologies, 4-roll machines stand out for allowing fully CNC-automated production processes, significantly decreasing the reliance on operators’ skills and, hence, making it the most suitable tech for mass-production.
SHORTEST FLAT END THANKS TO STURDY AND CLOSED FRAME
The frame constitutes, effectively, the back-bone of the machine. The stress generated during plate forming must be withstood by this critical component and, eventually, transmitted to the foundations. DAVI machines feature the most compact and closed frame on the market, which allows to: improve the rigidity of connection to the ground as well as machine stability; minimize deflections and displacement for the maximum rolls positioning accuracy; construct a much shallower and less expensive pit, due to reinforcement beams installed between frames (intra-frame design) rather than base platform. Based on extensive Finite Element Method (FEM) studies conducted by DAVI R&D, it is observed that the frame is particularly under stress while pre-bending. DAVI exclusive design features a much higher rigidity of the overall structure hence guaranteeing maximum accuracy even in the most demanding pre-bending and re-rolling operations.
TIGHTEST ACHIEVABLE DIAMETERS THANKS TO PLANETARY GUIDES
The bending power of a 4-roll machine is exerted to the plate by two side rolls. Unlike other solutions on the Market, DAVI exclusive design provisions a planetary actuation of the side rolls whereas, rather than being guided up and down, the mechanism rotates around a pivoting point. Thanks to this system: maximum performance thanks to force multiplier effect by leverage arm (distance between pivoting point and cylinder force application point); reduced top-roll deflection due to circular force application; forming the tightest diameters thanks to favorable geometry (with side rolls wrapping around small diameters cans).
BEST ROLLS PARALLELISM THANKS TO PATENTED SERVO-TRONIC© SYSTEM
The rolls movement is actuated by hydraulic cylinders installed at the two ends of the machine. The patented Servo-Tronic© system keeps the machine’s rolls parallel at all times thanks to its dual, independent but integrated, parallelism control system. This system features dedicated pumping groups and circuits guaranteeing that each cylinder receives oil at the very same pressure and mass flow, with electro-valves for fine-tuning only. In this way, even in case of electronics failure, the rolls parallelism is hydraulically and mechanically maintained and the machine can keep operating with excellent results. The Servo-Tronic© allows for: maximum accuracy of the rolls positioning; limited reliance on electronics with reduced downtimes in case of its failure; best geometrical tolerances on the workpiece; automatic compensation for unbalanced loads.
HIGHER TILTING CAPACITY THANKS TO PENDULAR GEARBOXES ARRANGEMENT
Both top and bottom rolls are motorized as a standard. Unlike other solutions available on the Market, exhibiting a bolted-rigid coupling of the gearbox structure to the machine frame, DAVI exclusive pendular arrangement provisions swingable connection between the motor gearboxes and the frame. DAVI pendular shaft-mounted gearboxes configuration allows for stress-free tilting of the rolls up to 100 mm (4”) every 3 meters (10 feet) rolls length. The Pendular Gearboxes arrangement allows for: free deflection of all the rolls under load, with limited stress on shaft-hub connection to the benefit of bearings reliability and durability; much higher tilting capacity for cones-forming
MACHINE READY FOR ACCESSORIES THANKS TO THE HIGHEST LEVEL OF CUSTOMIZATION ON THE MARKET
With more than 50 years of experience designing and supplying first class plate rolling machines, DAVI understands that every customer need is different. DAVI R&D Department will process your requirements and help you selecting the optimum technical and commercial solution to maximize as much as possible the return on your investment. For this reason, even the small and medium capacity machines solutions can be fully customized to better support the most diverse production requirements and industrial sectors. DAVI MCB machines are equipped with state-of-the-art control systems, specifically designed by DAVI R&D Department to help you getting the most out of your 4-roll plate rolling machine. Thanks to DAVI Industry 4.0 CNC, all your operators, even the most inexperienced ones, will finally have the capacity to comply with the required tolerances with maximum repeatability: a real boost to your competitiveness. Moreover, all DAVI CNC systems are expandable to allow retrofitting of auxiliary equipment (such as vertical and side supports, gantry loaders, etc.) at any time you may need it.
BEST OPERABILITY AND MAINTAINABILITY THANKS TO THE NEW DESIGN OF THE MACHINE
The improved designof the machine allows for increased operability during the whole process, provisioning: forged reinforced yoke (no welding) with large pivoting points for reducing the top-roll deflections; compact frames to easily eject the formed workpiece and to make extreme cones with no interference. Moreover, the planetary guides technology significantly reduces the required machine maintenance, thanks to: no need for regular lubrication with friction free movements (permanently lubricated bearings); maximum energy efficiency and durability with eliminated risk of guides wearing on accumulated mill-scale.
CATALOGS: Plate Roll Machines
NEW CONTROL SYSTEM
Optimized for 24/7 operations, functional and durable for any kind of workshop. Improved ease of use for the new smartphone-like HMI (Human-Machine Interface). Real-time fabrication fine-tuning thanks to high-res 3D simulation. 3D machine interface for an accurate live visualization of all the movements of the machine
The DAVI three roll MCP section roll was engineered to meet the requirements of very demanding customers, who need to bend large and extra large dimension parts with very strict tolerances.
From aerospace to shipyard, from automotive to structural, engineers are always designing solutions of more sophisticated bent parts, made out of hard material that can only be obtained by bending non-standard profiles at very tight diameters with strict tolerances.
- Machine Support & Service
- End-to-End Project Management