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Hydraulic control ROLCOX

of the rolls

Fixed Roller

Right

Left
Movable Roller

Next

Pump HT 1 M 01

Hydraulic oil tank

Left

Right

HT 1 M 01

Hydraulic pump

Fixed Roller

2
Next

HT 1 V 1/2

Retraction cylinder

Prop. valve left


Next

Retraction cylinder
HT 1 V 3/4

Prop. valve right


Next

Movable Roller

HT 1 V 10

Press cylinder
V 06

V 09

HT 1 V 11

Pressure decrease valve left


( one way valve )
Next
Pressure decrease valve right
( one way valve )
Next

V 07

HT 1 V 08
V 10

Retraction cylinder valve

V 11

Next
HT 1 V 06

Bypass valve left


Next

V 1/2

V 3/4

HT 1 V 07

Bypass valve right


Next

V 08

HT 1 V 09

Emergency valve

Pump HT 1 M 01

Hydraulic oil tank

Next

3
Roller dist. = 10 mm fix
+ Bearing dist. = 0 mm
Gap
= 10 mm

Next
Next
Next
Next

measured by

Gap sensor

Limit switch

RP - Frame

Retraction cylinder

Press cylinder

Fixed Bearing

Movable Bearing
Distance block

Next

Set points
Fixed Roller
Gap = 10 mm

Distance pieces

Right

Left
Movable Roller

L 0mm
Next

0 mm ( Bearing distance )

This is the point where the bearing distance is 0.


For the gap measuring this point is 4 m Amp.
The bearing blocks are fixed in a way that the
rollers can never touch each other physically

Roller distance 10mm = Gap 10 mm


Next

L min
Fixed Roller
Left

Gap = 25 mm
Movble
Movable Roller

Right

15 mm ( Bearing distance )

Distance between the bearings used as lower


limit for the pressure control.
If distance is less pressure control will be Next
deactivated.
GAP < L min Pressure control OFF
GAP > L min Pressure control ON
normal operation
Next

Roller

Roller distance 10 mm
+ Bearing dist. 15 mm
= Gap 25 mm

Next

Set points

Left

Fixed
Roller

Right

Gap = 35 mm

Roller distance 10 mm
+ L2 Bearing dist. 25 mm
= Gap 35 mm
L min
L2
Parameter set in the PLC. Set only once.
Range from 5.0 to 30.0 mm
Actual set point 25 mm

Movable

( Set point for material feeding )


Next
Next

Roller

Left

Fixed
Roller
Gap = 45 mm

Right

Roller distance 10 mm
+ L2 + 10 Bearing dist. 35 mm
= Gap 45 mm
L min
L2
+ 10 mm

Next

Until this value the rollers are pushed back


during start up the main motors.

Movable

Next

Set points

Left

Fixed
Roller
Normal operation
Gap = 65 mm maximum
Movable
Movable
Movable
Movable
Roller
Roller
Roller

Right

L min
L2
+ 10 mm

Roller distance 10 mm
+ Bearing dist. > 55 mm
= Gap > 65 mm
Next

Limit switch
Maximum distance allowed
between the bearings. ( 65 mm Gap )
Determined by a mechanical switch.
Over 65 mm gap the roller press will
stop with max. gap alarm.

Roller

Ok.
Next

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Start RP group
Fixed
Roller

Left

Right
At every start the emergency valve is energized
to close the hydraulic circuit.
Next
Next

Gap = 45 mm
Movble
Movable

To release the oil of the main cylinders the bypass valves


and the pressure decrease valves are energized (opened).
This will occur with standing rollers.
NextNext

Roller
PressRoller
cylinder

V 06

V 09

The movable roller will be moved


by the retraction cylinders
to L2 + 10 mm

= 45 mm

V 07

V 10

V 11

L min

Next
Next

L2
+ 10 mm
V 1/2

V 3/4
V 08

Pump HT 1 M 01

Hydraulic oil tank

After reaching of L2 + 10 mm, the main drives will be


started one by one.

Valve closed
Valve open

Next

Start RP group

Retraction cylinders are drawn back by springs.

Fixed
Roller

Left

Right

Gap = 35
45 mm

Next

L2

Movble
Movable

V 09

Gap = 35 mm

Next

In case if during moving back the movable roller an oil pressure


is measured of more than 40 bar ( normal < 40 bar ), the start will
be interrupted by an alarm signal.
Fault has to be acknowledged at the roller press after checking.

Roller
PressRoller
cylinder

V 06

After this the movable roller will be pushed back to


Next
L2 by the main cylinders from 45 mm to 35 mm.
This happens with running rollers.

V 07

V 10

V 11

Possible causes:
Material between the rollers.
Disturbance in the hydraulic circuit.
Roller can not move free.
After bearing distance is on both sides L2 the roller press group will
be released and feeding of the pre bin can be started.
Pump stops and valves will be closed.

V 1/2

Next

V 3/4
V 08

After L2 will be reached in pre bin the shut off Gate will be opened
to release material flow to the rollers.

Pump HT 1 M 01

Hydraulic oil tank

Next

9
Fixed Roller

Left

Right

Start Pressure control


After the start program is ready the pressure
control will start automatically.
Next
After opening of the shut off gate there will get
material between the rollers.

Movable Roller

Next
Press cylinder

V 06

V 09

The proportional valves will increase pressure to the


main cylinders up until the set point.
Hydraulic pump start.

V 07

V 10

V 11

V 1/2

V 3/4
V 08

Pump HT 1 M 01

Hydraulic oil tank

Next

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Fixed Roller

Left

Right

Pressure control
By the intake behaviour of the running rollers
combined with the pressure of the column ( gap )
of material on the rollers the material flow will
tend to press the rollers apart.

Movable Roller
Press cylinder

V 06

V 09

When the hydraulic reaches the


value set point-tolerance
the proportional valves will be closed
and the pump will stop.

V 07

V 10

Next

V 11

V 1/2

V 3/4
V 08

+ 10 bar
Pres.Set point
- 10 bar
At this value the material counter pressure
and the cylinder pressure will be on balance.

Pump HT 1 M 01

Hydraulic oil tank

Next

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Fixed Roller

Left

Pressure control

Right

100
90
bar
100 bar

Movable Roller

V 09

Next

Accumulator
Gas ( N2 ) Pressure = 90 bar

Start
up
125 bar
< 90 bar

Press cylinder

V 06

Pressure variations with in tolerance will be


compensated by the N2 accumulators.

Set point 125 bar

V 07

V 10

V 11

V 1/2

135 bar
125 bar
115 bar

V 3/4
V 08

Pump HT 1 M 01

Hydraulic oil tank


Next

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Pressure control
Fixed Roller

Left

Right

When the hydraulic exceeds the pressure (value)


set point + tolerance the proportional valves will open and the
pressure decrease valves will be opened (energized).
135 bar
125 bar
115 bar

Movable Roller

They will remain open until the set point


operation pressure + tolerance is reached.
After this the valves will be closed.

Press cylinder

V 06

V 09

Next

Note: This can happen at both sides at the same time but also
on one of both sides, depending of pressure measurement on
this side.
Next

V 07

V 10

20 m Amp

V 11

Characteristics of proportional valves.


V 1/2

Proportion valve
pressure
increase

V 3/4
V 08

30 %

100
%

V 10

Pump HT 1 M 01

Hydraulic oil tank

Proportion valve
pressure
decrease
Set point

12 m Amp
0%

100
%

8 m Amp

30 %
4 m Amp

Next

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Pressure control
Fixed Roller

Left

Right

When the hydraulic gets beneath the pressure (value)


set point tolerance the proportional valves will be
opened and the pump will start.
135 bar
125 bar
115 bar

Movable Roller

Next

This will remain so until set point operation pressure tolerance


has been reached.
After this the valves will close again and pump will stopped.

Press cylinder

Next

In this example on one side.


V 06

V 09

V 07
20 m Amp

V 10

18,4 m Amp

V 11

Characteristics proportional valves.


V 1/2

Proportion valve
pressure
increase

80 %

V 3/4
100
%
V 08

V 10

V 11

Proportion valve
pressure
decrease

12 m Amp
0%

80 %

Pump HT 1 M 01

Hydraulic oil tank


4 m Amp

Next

100
%

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Gap correction

A deviation in gap width between left and right


in permitted until a preset value.

Fixed Roller

Left

Right
Gap (r)

Gap (l)

A certain deviation is due to non homogenate mixture


of raw materials (coarse, fine, wet, dry).

Gap (l)

Movble
Movable Roller

Next

Gap (r)

If this value is exceeded the skewing will be corrected.

Roller
Press
cylinder
Presscilinder
Gap(l)
V 06

V 09

Gap(r)

Gap(diff)

V 07

Gap(diff)
V 10

> Gap(diff)toll.

V 11

Correction will be done first on the side with the bigger


gap by pressure increasing.
V 1/2

V 3/4

Correction is permitted until operation pressure + 5 bar.


V 08
V 10

This will remain so until gap - difference - tolerance


has been reached. Set point 4 mm.

Next

After this the valves will close again and pump will stop.
Pump HT 1 M 01

Hydraulic oil tank

Next

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Gap correction
Fixed Roller

Left

Right
Gap (r)

Gap (l)
Movble
Movable Roller

If skewing is after this correction still not within


tolerance limits, at the side with the smallest gap,
pressure will be released.

Roller
Press
cylinder
Presscilinder
V 06

V 09

V 07

V 10

This will remain so until gap - difference - tolerance


has been reached. Set point 4 mm.
V 11

Next
After this the valves will close again.

V 1/2

V 3/4

V 08
V 10

Pump HT 1 M 01

Hydraulic oil tank

Next

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Fixed Roller

Left
L(l)

Right
L(r)

Gap correction
and Pressure Control

Movble
Movable Roller
Gap (diff) < Gap (diff)toll. ( 4 mm )

Roller
Press
cylinder
Presscilinder

After this correction pressure control will be reactivated.


V 06

V 09

V 07

Next
V 11

V 10

V 1/2

If pressure difference between left and right exceeds a


preset maximum ( 30 bar ) an alarm will be generated
and pressure will be released at both sides.
Next

V 3/4

V 08

Pump HT 1 M 01

Hydraulic oil tank


Next

Fixed Roller

Left

Right

By means of to much adjusting of operation pressure or


due to changing material properties
the electrical load of the main drives can become to high.
If this load exceeds a preset maximum the pressure will
be reduced.

Movable Roller

This will last until the movable roller reaches


L2 + 10 mm = 45 mm gap
or until the drives get below operation load.

Press cylinder

V 06

V 09

Current control

17

Next

V 07

V 11

V 10

After this the pressure control will be reactivated.


V 3/4

V 1/2

V 08

Pump HT 1 M 01

Hydraulic oil tank

Next

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Fixed
Roller
Fix Roller

Left

Right

RP Group stop
At a stop of the roller press (desired or undesired)
the RP - slide gate will close and
stopped the material feed to the RP.

Movble
Movable Roller

The Pressure decrease valves will open,


the proportional valves will open,
and the emergency valve will open.

Press cylinder

Next

Roller

V 06

V 09

V 07

V 10

V 11

The rollers will due to material pressure move apart


until L2 is reached on both sides or after time limit.
Roller press will stop after 30 sec.

V 3/4

V 1/2

Next
V 08

Pump HT 1 M 01

Hydraulic oil tank

The Pressure decrease valves will close,


the proportional valves will close,
and the emergency valve will open.

Next

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Roller press
Dosing Gate

RP - Bin
Slide Gate.
opened
close
open

Dosing
Gate in
max. Pos.
min. Pos.
Dosing
Gate

Fixed
Roller

Open
the
Dosing
Gate

Movable
Roller

Last

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