HRB Series Plate Rolls HRB-4 Series Optional Equipment • NC Control • Polished Rolls • Side Supports • Profile Bending Rolls • Welding at Machine • Material Feed Table • CNC Control with Color Graphics • Oil Cooler • Vertical Support Crane • Changeable Top Roll (for smaller dia.) • Special Wind Tower Application Capacities Standard Equipment • Control Unit with DROs • Conical Bending • Bearing Seated Rolls • Stress Relieved Frame • Induction Hardened Rolls • PLC Synchronized Side Rolls • Hydraulic Top Roll Opening • Pressure Adjusted Bottom Rolls • Bend Length 5 – 20’ • Bend Thickness ¼” – 6” HRB-3 Series Optional Equipment • Variable Speed Control • Oil Cooler • Vertical Supports • Welding at Machine • Special Wind Tower Application • Changeable Top Roll (for smaller dia.) • Polished Rolls • Side Supports • Profile Bending Rolls • Material Feed Table Capacities Standard Equipment • Control Unit with DROs • Conical Bending • Bearing Seated Rolls • Stress Relieved Frame • Induction Hardened Rolls • PLC Synchronized Side Rolls • Hydraulic Drop End with Easy Remove • Pressure Adjusted Bottom Rolls • Bend Length 8 – 13’ • Bend Thickness ¼” – 1” Engineering Engineering & Production Advantage The mechanical and hydraulic systems on HRB4 machines are designed by experienced Durma engineers. These engineers utilize parametric 3D engineering technology (Pro/Engineer) as well as static and mechanism analysis. All mechanical, hydraulic and electronic systems are designed and tested by Durma electrical and mechanical engineers. Only following lengthy tests and evaluations are the machines authorized to be manufactured into serial production. Features Simple Operation Four-roll bending machines, by design, are safer, faster, more productive and user friendly than three-roll machines. The bottom roll, which is positioned on the same Y axis as the top roll, secures the sheet edge for accurate pre-bending and minimized “flat” zones at the sheet edge. The two side rolls are controlled independently. Parallelism is assured by the support of the two side rolls during the bending process. Forming is achieved by securing it between the top and bottom roll. CNC bending of polycentric and elliptical shapes is easily achieved with this design. Features Planetary Guides Planetary Guiding All rolls with 17” or smaller diameter are equipped as standard with a planetary guide system. In this system, swing arms are used for guiding the rolls, allowing them to function as two independent axes moving along an arc. Material spring back is also minimized. Two rolls are driven as standard, with an option to have all four driven. A 1.1” minimum diameter of the top roll can be achieved. The side rolls are guided by swing beds which hallow them to act as two independent axes moving in a planetary plane. Machines 1 3/8” have a dual planetary gear system. The system allows bending of diameters as small as 1.2 times the top roll diameter. Side rolls position in a planetary approach to the top roll, allowing better pre-bending as well as minimizing spring of the material that occurs during the bending process. Features Precise Roll Positioning Side rolls are triggered by four independent and oversized hydraulic cylinders. Synchronization between the rolls is realized by combination of magnetic rule measurement and PLC’s achieving response within milliseconds. High precision load-holding valves working with a torsion bar system is used for roll parallelism. Sheets of different thicknesses are secured without part deformation. Hydraulic Drop End For easy part removal, the end frame assembly is hydraulically lowered to facilitate part removal. Strong Guiding Systems Top rolls are guided with spherical roller bearings. The bottom and side rolls are seated in bronze bushings. Features Induction Hardened Rolls Stress Relieved Frame The machine frame and connections are stress relieved after the welding process. The completed frame is machined in a single pass with one position on the five axis CNC machining center. In this way, parallelism of all axes and surfaces is precisely machined, assuring long-term durability and the ability to produce accurate parts. Four Rolls Drive System Features Durable Rolls & Crowning The most important element of plate roll bending machines are the rolls themselves. In some cases, builders can use weaker rolls, allowing bending diameters to five times the material thickness. Durma machines can achieve diameters to 1.2 diameter of the top roll. Highly durable carbon steel (C45) rolls are machined by CNC lathes with high precision without creating a notching effect. Work surfaces of the rolls are induction hardened to HRC 54+/- 2 and hardness tests are done from different points. A crowning shape is machined into the rolls to compensate for deflection that can occur during the rolling process. Special crowning for different materials can be applied free of charge. Features Conical Bending With Durma’s strong frame and angular bottom and side rolls, wide angles and small diameter conical parts are easily bent. While some machines on the market allow minimum conical bending of three times the top roll diameter, Durma HRB4 machines can bend to a diameter of 1.5 times that of the top roll. Features High Torque Roll Triggering Durma Rectilinear Rolls Because of its high torque, the HRB bends parts with fewer steps. All rolls are activated by independent high torque hydraulic motors and planetary gear boxes. The activation system is positioned on the same axis as the roll, so high torque is transferred to the sheet without any power loss. On machines with roll diameter larger than 17” a rectilinear guide system is used. This system moves in a straight line, not a curve as in the planetary system. This results in a better, more stable system for pre-bending and rolling heavier plates. All four rolls are also driven in this system. Features High Torque Drive Hydraulic & Electrical System Machine movements are triggered by hydraulic components. The system consists of well-known electrical components, such as Siemens, Schneider, Phoenix and Opkon. The system is protected by current overloadings for its components, power supplies, electronics and motors. Bosch Rexroth valves provide quick and accurate response time. Overload pressure valves are used to withstand peak pressures and eliminate system overload damage. Planetary Swing Rolls Control Systems PLC Control System A PLC control system ensures the machine’s bottom and side rolls operate synchronously. Up to five steps can be programmed with the touch screen. The PLC controls six different axes, therefore reducing setup times. Control Systems NC Control System • Dedicated scratch-proof, oil-proof, acid-resistant IP65 sealed membrane push buttons with 51 keys and fiber optic communication lines • AMD Geode TM LX 800 500MHz • Memory: 256MB DRAM for CPU, 1MB SRAM for parameters • Color TFT-LCD 7” WVGA (16:9) resolution (800x480 RGB) 262,144 colors. • 1 Ethernet port, 1 CAN interface, 1 RS232C serial port, 2 USB ports, 1 VGA output • Software: • Manual, teach-in and automatic working modes • Standard 7 axes (X1, X2, Y1, Y2, P, P1, Z) • Conic and parallelism control adjustable speeds • 100 step, 2500 program memory • User friendly program editor • USB port for programs backup • Part pcs programming • Working hours counter, mm/inch system • Automatic turn-off programming • Turkish, English, German, French, Spanish, Italian, Russian and Polish languages • Alarm list Control Systems CNC Control System The CNC control system, in addition to the NC control system with its graphical control system, allows bending to be done step-by-step or can automatically calculate the bending steps without the need for operator skills. This user-friendly CNC features: • 12” TFT S VGA color display with anti-glare screen • Ergonomic molded plastic cabinet • Dedicated scratch-proof, oil-proof, acid resistant IP65 sealed membrane push button keyboard with 53 keys • Interactive graphic editor for work piece and tool data entry • Automatic identification of the best bending sequence(s) • Programming of the axes positions in tabular mode with automatic syntactical checks • Multi-channel ISO interpreter • Internal memory for 10,000 programs • CPU Intel 486 or Pentium, FPGA integrated logics, surface mounting, fiber optic, solid state display • 1 serial port RS232, 1 parallel port • Standard 32 inputs and 32 outputs • Remote I/O system, connected through optic fiber link. Optional Features Vertical Working Feature When performing large scale bending, the horizontal floor space required can be substantial. Providing there is vertical clearance, vertical positioning and bending can reduce the required floor space considerably. Separate Power Cabin If the working area is dirty, a separate hydraulic and electrical system is preferable as it extends the life of the machine and enables easy maintenance and handling. Vertical format bending also eliminates the need for side and vertical material supports that are required to reduce distortion and stretching that occurs when horizontally bending. When desired, the machine can also be used horizontally. Optional Features Extended Rolls Automated Roll Bending Extended shafts can be ordered for the bending of profiles such as tube, square and round profiles. When production volume requires, different automated concepts are available. Optional Features Vertical or Special Sheet Support Systems Optional hydraulic side or vertical support devices are available to reduce sheet stretching and deterioration during bending of large sheets. Moveable gauges with hydraulic double cylinders are produced from st52 steel construction. It can be supplied according to different tonnage and height. Roll Shapes Learn More Videos Playlist (3 videos) 4 Roll HRB Series HRB 3065 Wind Tower Application Datasheets View Online Printer-Friendly Version Durma Aims for Continuous Development DURMA’s large investment in machining centers and production equipment, as well as its ISO-certified factories totaling 1,350,000 square feet and 1,000 employees, make one of the world’s largest, efficient and most contemporary facilities in the world. In order to offer customer solutions and further develop patents, the DURMA Research and Development center opened in 2010. Fifty engineers were added over the last two years. Designed and engineered with modern technology, DURMA products are equipped with high quality and proven readily available components. Established in 1956, DURMA has vast experience in building and supplying quality products. With over 60,000 machines delivered worldwide, DURMA has earned the reputation as a supplier of innovative, “value oriented” solutions. Your partner today, tomorrow and forever.