Fabrication Machinery Solutions

CARELL 4 roll plate rolls are advanced sytems are: FFD - Full Frame Extended Design ALG - Anti-friction Linear Guides HMB - Heavy Multiple Bearings AST - Anti-friction sliding technology HTT - High transmitted torque BACK TO TOP The Powerful and Reliable Choice Full Frame Extended Design Parmigiani plate rolls have the most heavily sized frame you can find in the market. Unlikely slim frames covered with thin thickness plates that you can find on all machines in the market, makes our frame design look definitively oversized.The exclusive full frame design withstands all bending forces and guarantees stiffness and performance throughout years of service.This unique machine frame, with extended design for added rigidity and strength, are welded fabrication. After welding all frames are stress relieved and then machined on CNC milling machines Get more with our linear guide s ALG System (Anti-friction Linear Guides) • No friction - less than swing design • Direct load to the plate • Less vertical power on top roll • Lower bending diameter The linear guide design is the only system that can grant the necessary machine stiffness and the perfect geometry for all kind of bending operations. The linear design allows a compact geometry of the machine ("minimum centerline distance between the two side rolls", impossible to obtain with the swinging design) that is essential for bending precision and accuracy. The linear design allows you to work in the best and ideal geometrical conditions when rolling high yield strength materials, reducing the shell spring back reopening effect and obtain a much smaller bending diameter when compared with the swinging design • Heavy Duty HMB Exclusive Design • Supports Cone Rolling • Permanent Lubrication Built for Heavy Work HMB System Heavy Multiple Bearings More power - More torque HTT System (High transmitted torque) Each bending roll is supported by 4 heavy-duty self-aligning spherical roller bearings (double raw type). Each bearing is oversized in order to withstand the whole bending load. Thanks to the HMB exclusive design, with four oversized bearings fitted into a swiveling housing, the roll can freely deflects along it’s full width during the rolling process. This guarantees an optimal distribution of the load on the supports even during the cone rolling process and increases the machine's reliability and life. Moreover, the multi bearing system with swiveling housing design greatly reduces the maintenance and the need for lubrication (permanent lubrication). Friction free - Maintenance free AST System Anti-friction sliding technology Each Rolls support is machined with anti-friction material in the sliding area. This system drastically reduces the maintenance and sliding friction, less than in a planetary machine. The rolls driving is realized by independent hydraulic motors via planetary gear transmission directly coupled to each driven roll. The independent rolls hydraulic drive assures and automatic speed compensation between the top and lower rolls and an optimal distribution of the torque on each roll during the working phase. The HTT system allows the best plate feeding and the highest driving torque of any competitive machine. A winning combination for those looking for performance of the highest level. VBH Options BACK TO TOP Great Options and Accessorie s Our Parmigiani VBH has a standard package of features that usually are not available even as options in other machines (like our FACILE, i-Diagnostic, calibration working mode, Servo-dynamic Active Control with infinitely variable positioning speeds of the bending rolls and active pressure control of the lower roll...) our R & D department has designed a wide range of accessories for special bending applications, like the Hydraulic cambering device for central lower roll with variable intensity for working with thin and long plates, gantry loaders, unloading devices etc. in order to increase productivity and quality of finish for special materials. OPTIONS

CARELL 4 roll plate rolls CNC Control Options are an essential element for executing precision rolling applications. Select the "SAVE&BEND" with its 10.4” display or the "FAST" with a 15” display or the "STRADIVARI" equipped with a 19" display and "3D ROLLCAD" for a greater experience in plate rolling. BACK TO TOP VBH Controls DIGIMATIC VBH Controls BACK TO 4ROLLS Everything is under control Dedicated controls from PARMIGIANI for plate rolling cover an entire range of applications. All software is developed in-house by Parmigiani technicians with great experience in plate rolling. From the simple, compact DIGIMATIC control to the STRADIVARI (unlimited number of axis) there's a PARMIGIANI control for nearly every application. 4 LEVELS OF CONTROL ! Parmigiani NC and CNC controls are 100% developed in-house DIGIMATIC SAVE & BEND FAST STRADIVARI Controls are an essential requirement for executing precision rolling applications. Select from the "DIGIMATIC" , or " SAVE & BEND" with its 10.4” display or the "FAST" with a 15” display or the "STRADIVARI" with a 19" display. Our controls function just like a tablet with touch-screens: navigating through the options is simplified via menus, shortcuts and with context-sensitive help. ® DIGIMATIC 7” full color display, touch – screen N° 6 digital read-outs, for Central Lower and Side rolls. With 2 digital read-outs for each bending roll. The operator can read exactly the inclination of the roll during conical bending. N° 1 digital read-outs, for Central Lower roll pinching pressure 7 Controlled Axis It’s possible to create different programs, saving the pinching pressure of the lower roll and the positions of Lower and Side rolls for the automatic positioning (step by step) Storage Memory Capacity: up to 500 programs of 26 steps each. BACK TO TOP SAVE&BEND FAST ® SAVE & BEND PARMIGIANI “SAVE & BEND”: NC Control type This is an entry level NC with 9 controlled axis, for fully automatic working mode. 10.4” color display, touch–screen 9 Controlled Axis (can be upgraded up to 16 axis) Two methods of programming: Editing and Play-back modes Storage Memory Capacity: up to 1000 programs of 50 steps each. BACK TO TOP ® FAST PARMIGIANI “FAST”: CNC Control type with Automatic program mode for single radius shapes: the control automatically creates the complete bending program, simply entering the shell data (radius, thickness, width, type of material), with all the sequence for obtaining the required shape. If necessary the program theoretically calculated by the control can be optimized by the operator. 15” full color display, touch – screen 9 Controlled Axis (unlimited upgradeable number of axis) Three methods of programming: Aided, Editing and Play-back modes Storage Memory Capacity: up to 5000 programs. BACK TO TOP STRADIVARI ® STRADIVARI WITH 3D ROLLCAD Discover the most advanced 3-D CNC T he " STRADIVARI" with 3D ROLLCAD on a 19" display functions just like a tablet with touch-screens: navigating through the options is simplified via menus, shortcuts and with context-sensitive help. Providing an easy-to-use operator experience. MORE ABOUT STRADIVARI BACK TO TOP

CARELL 4 roll plate rolls equipped with advanced technology sytems are: i-DIAGNOSTIC - immediate fault detection system PARALLELISM System - proportional valves hydraulic flow control FACILE - Electric Component Plug and Play connectors HI-TECH HYDRAULICS - Infinite variable hyraulic speed and pressure control BACK TO TOP VBH Technology Active Extended Diagnostic Everything is under control Are you loosing production hours and days checking around the machine for which connection wire, PLC card, push-button or fuse are faulty?… Forget these kind of problems with PARMIGIANI's i-Diagnostic system for immediate fault detection. The i-Diagnostic is a revolutionary diagnostic system that supervises all the main functions of the machine, with an easy to use and intuitive control panel interface. From the touch-screen you can control almost all electrical connections around the machine; all PLC modules; all micro-switches (You can check also if they are engaged /energized or not) and more....i-Diagnostic: a revolution in customer support. Instantaneous fault detection instead of troubleshooting Detailed information on type and location of the fault VBH Technology I-DIAGNOSTIC The PPS is the most advanced parallelism system available on the market today. The rolls parallelism in a plate bending machine is a key factor for production accuracy. The capability to maintain precision over years of performance is also another critical point. For this reason we employ the best of today's available technology with digital control systems and hydraulic flow control via proportional valves. We have designed a system resistant to wear that will give you years and years of trouble free performance, keeping the machine positioning precision just like your first day of operation! The top and bottoms rolls parallelism is fully controlled by a digital “high speed” FIELD BUS system. The package includes a set of hydraulic proportional valves with high performance digital control cards, matching the high speed of the FIELD BUS system. This digital technology (the loop control is 20 times faster than PLC-based electronic controls) joined with the hydraulic proportional valves, provides a parallelism precision of about 0.1 mm. Parallelism System Digital control technology with hydraulic proportional valves Parallelism precision 0.1 mm BACK TO TOP PPS HYDROTRONIC Plug and play technology Do It by yourself "Assemble and plug in – that’s all!" Quick and simple plug connections replace elaborate wiring. • Avoids wiring errors • Shortens start-up time • Quick swapping of cables  The wiring of the machine is achieved by Plug and Play connectors and digital distributors. The cabling system with connectors is more reliable over time, resistant to environmental contamination and vibration and allows for quick and easy maintenance. With our FACILE® Plug and Play system you can change a wiring connection (to the hydraulic valves or the encoders or potentiometers, to a micro-switch etc…) with pin plug connector, without unscrewing any electrical wire. Same procedure for all PLC modules! Without the need of a skilled electrician! With the purpose of increasing your independence from third parties all software are loaded in static memory cards, (like the ones used in digital video cameras) and not in volatile Eprom! This means that you will almost never lose the software, even when you need to change the PLC unit. Our plug-play system is a military approved technology! Digital control technology with hydraulic proportional valves Parallelism precision 0.1 mm Advanced Wiring System BACK TO TOP FACILE Advanced Hydraulic System Infinitely variable adjusting speeds Infinitely variable bending pressure BACK TO TOP The hydraulic system is the operative core of your VBH: it runs everything from the bending rolls drive to the bending rolls movement, tilting and all other machine attachments. This is why we invested a lot in research and development to give you a smooth, precise and highly responsive system. Through digital controls the system is managed by dedicated hydraulic proportional valves (pressure and flow) that allows you to select the most convenient speed during each production step (vs. other brands machines that give you only one or two selectable speeds) and the maximum central lower roll pinching force in order to adapt it to the characteristics of the plate being worked. The possibility to select low pressures for thin plates widely extends the range of the machine. With infinitely variable pressure and speed adjustment the operator will have full control of the process in any bending situation. HI-TECH HYDRAULIC

Initial Pinch or Single Initial Pinch Plate Rolls are for lighter capacity applications and may be electro-mechanical or hydraulic that make them ideal for adjustable, cost effective production. BACK TO TOP INITIAL PINCH PLATE ROLLS Precision Engineered H ydraulic & Mechanical Dependability Backed by the Best Guarantee in the Industry! Request-A-Quote Carell Corporation provides superior quality "slip rolls", "initial pinch rolls" and three roll plate rolls. Where the bending sequence is performed by "pinching" the flat sheet between two counter-opposed rolls while the third offset roll or "bending roll" moves upward to contact and bend the sheet. Extraction methods are equipped with either forward tilting, a releasing top roll or a removable end yoke. They are generally designed for lighter capacity applications that makes a cost effective solution to your production! Click Image, Links or Scroll Down for descriptions, standard equipment, options & technical specifications RM & HRM SERIES 1 2 Ga to 16 Ga • 3' to 6' Long IRM SERIES 14 Ga to 3/16" • 3' to 8' Long Shown with O ptional LED Readout TSI SERIES 20 Ga to 1 /4" • 3 ' to 6' Long HTSI SERIES 20 Ga to 3/8" • 3' to 10' Long MRM- SERIES 1/8" to 1/2" • 3' to 12' Long We manufacture and stock; tools for bending, tube rolls, pipe rolls, special tooling and custom tooling. We also carry the following brand names Parmigiani, Comac, Memoli, Omcca, Simasv, Isitan, Icaro, Offmer & More! RM & H RM SERIES 3 ROLL , SINGLE INITIAL PINCH PLATE ROLLS BACK TO TOP RM Series STAN DARD FEATU RE S RM Models have manual adjustment of the lateral bending roll via single hand wheel a nd precision worm drive jack screw boxes. Lateral bending roll can be mechanically tilted for cone rolling. LED Readout to monitor the position of the lateral bending roller Har dened & polished rolls Cone device and rod grooves are standard and identical to HRM Series models. HRM Series STANDARD FEATURES Lateral Roll is HYDRAULIC actuated from the control console with joystick controlled tilting action for rolling cones. Roll is idle in rotation and has 3 round rod grooves LED Readout to monitor the position of the lateral bending roller Induction Har dened and Polished Surfaces on all 3 rolls Co ne R olling Device for rolling conical shapes Both Upper and Pinch rolls driven by electric motor and oil bath speed reducer through NiCrMo solid stock gears Pinch Roll Pressure adjustment via ergonomic easy adjust cam lever Lateral Quick Release Top Roll with safety lock 24V Low voltage controls, Foot Pedal Rotation, E-Stop, Safety Trip Wires, Instruction Manual RM & HRM SERIES SPECIFICATIONS RM & HRM SERIES IRM SERIES BACK TO TOP 3 ROLL , SINGLE INITIAL PINCH PLATE ROLLS CARELL IRM SERIES units are 3 roll, single initial pinch plate bending machines with powered rotation of both top upper and lower pinch roll. Choice of 10 models from 3' to 8' long in 14 Gage to 3/16" capacities. Suitable for medium to low production runs, Affordable & Efficient!. IRM SERIES STANDARD FEATURES Both Upper roll and Central Pinch rolls driven by electric motor and oil bath speed reducer through NiCrMo solid stock gears Base in steel, electro-welded and cast steel shoulder frames, all stress relieved Lateral roll, idle in rotation with manual up/down adjustment via single hand-wheel Central pinch roll adjustable manually via single hand-wheel Front quick release top roll with rotation lock out safety switc Lateral roll movement via electric motor and heavy duty worm gear drive for precise positioning and maximum power Cone rolling device is standard equipment Lateral bending roll and pinch roll incline for cone working Low voltage push button controls and foot pedals for rotation control w/ E-Stop Multi point safety system including circumferential trip wire Manual forced lubrication Instruction manual Wire / rod grooves on pinch roll and lateral bending roll IRM SERIES OPTI ONS Induction hardened and polished rolls LED Digital Readout Powered Lateral Bending Roll Adjustment up/down IRM SERIES SPECIFICATIONS IRM SERIES TSI SERIES BACK TO TOP POWERED INITIAL PINCH PLATE ROLLS STANDARD FEATURES Frames heavy solid steel alloy sheet, CNC machined and stress relieved Lateral roll, idle and moving on roller bearings Pinch roll positioning via heavy duty screw jacks with single manual hand wheel Manual d rop end top roll yoke (w/ lock out safety switch and set lock) Lateral roll movement via precision heavy duty worm gear and manual wheel crank or optionally powered up/down by efficient drive train system Lateral bending roll is adjustable in incline for cone rolling Bending & pinch roll equipped with analog digital counters for repeat reference position Low voltage foot pedal stand for CW/CCW rotation with E-stop palm button Multi point safety system including circumferential trip wire Illustrated Instruction manual w/ electrical schematics The Carell TSI Series is a 3 roll, single initial pinch plate bending machine with precision adjustment of lateral bending roll and powered rotation of upper and lower pinch rolls using hig h efficiency motor/reduction unit. They are designed to work with 16 GA x 48” wide material in capacity. FIVE YEAR Limited Frame Warranty! Shown with O ptional LED Readout NOTE: With O ptional LED Readout and/or Optional Powered Bending Roll, machine controls are push buttons on a mobile console in lieu of foot pedals. TSI SERIES SPECIFICATIONS TSI SERIES HTSI SERIES HTSI SERIES 3 ROLL HYDRAULIC INITIAL PINCH PLATE ROLLS BACK TO TOP The CARELL HTSI SERIES unit is a 3 roll, single initial pinch plate bending machine with powered adjustment of lateral bending roll and powered rotation of upper and lower pinch rolls. STANDARD FEATURES Both Upper roll and Central Pinch rolls driven by electric motor and oil bath speed reducer through NiCrMo solid stock gears Base in steel, electro-welded and stress relieved Lateral roll, idle and moving on roller bearings Central pinch roll pinch pressure adjustable by precision worm gear movement Front quick release top roll with rotation lock out safety switch Lateral roll movement via electric motor and heavy duty worm gear drive for precise positioning and maximum power Lateral bending roll and pinch roll incline for cone working Low voltage push button controls via mobile control console Multi point safety system including circumferential trip wire Forced central lubrication system with pump and tank Instruction manual HTSI SERIES SPECIFICATIONS MRM-H SERIES 3 ROLL HYDRAULIC INITIAL PINCH PLATE ROLLS BACK TO TOP Carell MRM-H Series are Fully Hydraulic 3 Roll Initial Pinch Plate Rolls with HYDRAULIC bending roll, pinch roll & drop ends MRM-H SERIES STANDARD FEATURES Lateral Roll is HYDRAULIC actuated from the control console with joystick controlled tilting action for rolling cones. Roll is idle in rotation (Round Rod Grooves Optional) 2 LED Readouts to monitor position of bending & pinch rolls Induction Hardened & Polished Surfaces on all 3 rolls Cone Rolling Device for rolling conical shapes Both Upper and Pinch rolls driven by electric motor and oil bath speed reducer through NiCrMo solid stock gears Pinch Roll Pressure adjustment via push buttons Hydraulic Drop End for quick and easy removal of the work piece 24V Low voltage Push Button Controls, E-Stop, Safety Trip Wires, Instruction Manual OPTIONS: Rod Grooves, Lateral & Overhead Material Supports, Variable Speed, 2 Speed Rotation, Custom Lengths and Dedicated Configurations MRM-H SERIES SPECIFICATIONS MRM SERIES MRM-S SERIES Powered 3 ROLL INITIAL PINCH PLATE ROLLS BACK TO TOP MRM-S Standard Features This mechanical model is designed for light to medium jobs. It is used in jobs up to 10 mm thickness materials. It is used in Aluminium Bendings, Air Conditioning Channels, Advertising Panels and Sheet Metal Covers. All models are planet reducer driven SAE 1050 (CK 45) Quality Certificated Steel Rolls with high tensile strength Steel Welded Main Frames Mechanical manual openable dropend Mobile Control Panel Conical Bending Device Central lubrication system Top roll support system and with planetary reducer Precision Bending with Brake Motor Motorised Adjustment of Back Roll Built according to EC Safety Directives (CE certificate) User’s manual . CALL ONE OF OUR SALES & APPLICATION ENGINEERS FOR DETAILED INFORMATION AND PRICING

CARELL's 3000 Series Hydraulic Angle Rolls Has Become The Industry Standard for a New Generation of Highly Efficient and Versatile Machines with Unparalleled Standard Features ANGLE ROLLS CARELL 3000 Series Hydraulic Angle Rolls , O ur 3000 series of Angle Rolls has Become the Industry Standard for a New Generation of Highly Efficient & Versatile Machines with Unparalleled Standard Features OVERVIEW: The Carell 3000 series of angle rolls gives fabricators a wide range of choices from small footprint to large plant equipment, all designed for long life, reliability, consistent fabrication output, and heavy-duty application. This is particularly beneficial when companies and clients need angle rolls for applications where the workspace is limited in size and scope. When you need manufacturing equipment that is going to deliver consistently, get the right choice for your shop or production line the first time… Start with Solutions from Carell. GALILEO SERIES 302HV 303HV 304HV 305HV 308HV 306HV 309HV 307HV 310HV4 311HV4 312HV4 314HV4 MIGNON SERIES Scroll Down to Click Images & Links for descriptions of standard equipment, options & technical specifications Note: CNC Control option requires external compressed air supply for the pneumatic actuated encoder, 75 to 80 psi 3000 SERIES ANGLE ROLLS 302HV thru 304HV Series BACK TO TOP 302HV Angle 2" Pipe 1-1/4 " - F lats 2-3/8" 303HV Angle 2- 1/4" Pipe 1-1/2 " - Flats 3" 30 4HV Angle 2-1/2 " Pipe 2" - Flats 4" 302HV-304H 305HV thru 308HV Series 305HV Angle 3 " Pipe 2 -1/2 " - Flats 5" 306HV Angle 3 -1/2 " Pipe 3" - Flats 6 " 307HV Angle 4" Pipe 4" - Flats 7" 308HV Angle 4 -1/2 " Pipe 5" - Flats 8" BACK TO TOP 305HV-308H 309HV thru 311HV4 Series 309HV Angle 5" Pipe 6" - Flats 9" 310HV4 Angle 6" Pipe 6" - Flats 10" BACK TO TOP 311HV4 Angle 6" Pipe 8" - Flats 12" 309HV-311HV4 GALILEO & MIGNON Series BACK TO TOP G50 Angle 2- 1/2 " Pipe 2" - Flats 4-1/2 " G80 Angle 3 " Pipe 3 " - Flats 6 " Model-00 Tube 3/8 " - Flats 3/4 " Model-025 Tube 7 /8 " - Flats 1-1/2 " 312HV4 Angle 8" Pipe 10" - Flats 16" 314HV4 Angle 10" Pipe 12" - Flats 20" 312HV4 & 314HV4 Series BACK TO TOP 312HV-314HV GALILEO-MIGNON

Carell's 2 Roll Plate Rolls are designed to rapidly produce radius and cylindrical parts from start to finish at the touch of a button in a cost-effective manner. BACK TO TOP 2 Roll Plate Rolls Perfect Rollin g Without Surface Marring or Contamination! Request-A-Quote Our 2 Roll Units are designed to rapidly produce radius and cylindrical parts from start to finish at the touch of a button in a cost-effective manner. Machines engineered for high speed continuous production. Easy setup using durable mechanical and electric limit devices. Add an auto loading and ejector system and the unit becomes a powerful tool, reducing part throughput & handling time to an absolute minimum. STANDARD FEATURES High speed one pass rolling Quick set-up and adjustment Eliminates leading flat ends Tight tolerance rolling of round parts even using sheets with cutouts, voids and perforations Machine frame in heavy steel plate and structural sections, electro-welded, stress relieved and precision CNC machined Urethane roll driven by electric motor, inverter and gear reduction or hydraulics Powered drop end actuated in automatic or push buttons Top roll sheet support arm, manual preset, max. diam. 27” All rolls mounted in spherical roller bearings Urethane roll stroke setting via precision dial gauge hand wheel or electrics Urethane roll pinch carriage up/down by hydraulics Sheet feed support with squaring arm Low Voltage Controls, mounted on detached command pulpit with push button controls, positive leveling of lower roll Manual forced lubrication OPTIONAL EQUIPMENT Sheet-Loading systems Cylinder ejector systems Automated sheet alignment systems Sheet pallet shuttle systems Special machine configurations for dedicated production jobs Various Overhead Support configurations NC & MULIT-AXIS CNC Controls for Automatic Production 2 Roll Models are available in lengths From 20” to 78” and 28 Ga to 0.125” thickness Dedicated Cylinder Rolls or Dedicated Cone Rolling Machine No finish deterioration of part surface The High Durometer Urethane coated lower roll allows perfect rolling of polished aluminum alloy, stainless steel or mirror finished materials without surface marring or contamination. Reduce / Eliminate un-bent flats and produce perfectly aligned seams with maximum pressure between the top and pinch rolls, perfectly parallel seams are achieved with virtually no un-bent flats. Choose from over 30 standard sizes. All can be tailored to your specific production needs. Carell 2 Roll Auto-cycle machines can also be built as production cells Q-SERIES

Carell Corporation offers Plate Rolls, Angle Rolls, Rebar Benders, Tube/Pipe and Ornamental Benders, Automated & CNC Controls are available. Request Dealer Info 1993 8142 Over 100% 31 Year Established Machines Placed in North America 12 Month Part Warranties Years of Service Products: Ready to Deliver! Carell provides the broadest range of manufacturing machines, options and tooling to match any budget or application. Our expanded machine shop can satisfy the growing demand for custom tooling of any complexity. Support: Best in the Industry! Carell offers expert support for the life of your machine. Our Sales Technicians can rapidly assist you with application evaluations, solutions and technical information. We are designed to Roll! Service: Certified Technicians Carell's in house service department keeps all of our machinery in a perfect state of readiness for immediate shipping. Our Service & Support are an ADDED VALUES to every machine sold. We are here to assist you during and after the warranty period.

Plate rolling is one of the most complex metal fabrication processes. Changing just one variable directly affects numerous others. Today many plate rolls have CNCs with data tables that draw from decades of rolling experience, which has made the process much more predictable. Request-A-Quote BACK BACK BACK BACK BACK BACK BACK Published Articles: "Plate Rolling Rolls On" By: Francesco Massa Advanced controls make a highly variable process more predictable. Click here for PDF Comprehensive Guide to Plate Rolling Machines "A Rundown On Rolling Machines" By: David Donnell, President, Carell Corporation The type of bending application determines the style of machine and bending capacity needed to do the job. Click here for PDF See Below for Quick References by Subject - More About Roll Forming - BACK TO TOP Plate Roll Bending Selection Guide Plate rolling is one of the most complex metal fabrication processes… Changing just one variable directly affects numerous others. Today many plate rolls have CNCs with data tables that draw from decades of rolling experience, which has made the process much more predictable. With predictability also comes automation. Some plate roll operations now have automated the loading, rolling, and unloading, producing precisely rolled workpieces time after time. QUICK LINKS Quick Links by subject: Plate Roll Manufacturers Machine Capacity Pre-Bending vs. Rolling Ratings Pre-Bending Ratings Rolling Ratings Automation Three Roll Initial Pinch Double Pinch Automatic NC or CNC Controls Variable Geometry Plate Rolls True Pyramid Machines Two Roll Machines Vertical Format Plate Rolls Optional Equipment & Accessories Cone Rolling Devices Lateral & Overhead Supports Extended Roll Shafts Roll Movement Up/Down Roll Balancing Plate roll manufacturers Plate roll manufacturers commonly rate machines according to baseline material yields between 36 to 38,000 psi. When choosing a roll you must refer to your mill delivery certificates, to your proposed supplier or to the Internet to specifically verify the average yields of the plate you need to roll. In our current manufacturing environment, the term “A36 Steel” has little correlation to the actual yield since the A36 generalization encompasses many specific sub-denominations. Some of these may have yields strengths of 70,000psi or more. The old common term “Mild Steel” will generally represent steels with yields of 45,000 to 55,000 psi. Machine capacity must be commensurate to your material yield. Most roll manufacturers can provide tables or graphs that allow you to match machine capacity to the material yield. Pre-Bending vs. Rolling Ratings will often be presented in numerous formats and tied to a minimum shell diameter at a given thickness for each Plate Roll model. The Pre-Bending operation is performed at the leading and trailing edge of the sheet (in most cases, the eventual seam). Sheets cannot physically be bent completely to the leading edge and will thus leave what is referred to as an ‘Unbent Flat’. As a rule of thumb, the minimum you should expect for an unbent flat length is 1.5 times the material thickness. This may approach 2.5 to 3.5 times the material thickness for thicker plate. It is this pre-bending operation which attempts to reduce the unbent flat to the minimum possible length which requires the most power from the machine. This operation is also very critical as care must taken to ensure that the sheet does not disengage from between the rolls. Because of this “safety factor” claims of unbent flats equal to 1.1 times the material thickness should be thoroughly investigated as it is rare that this can be achieved. Pre-bending ratings with the shortest possible unbent flats are necessarily lower than the overall rolling capacity rating for any given machine. You must be mindful when reviewing machine ratings since the maximum total rolling capacity is generally expressed with the intrinsic requirement of multiple rolling passes, longer un-bent flats and larger minimum shell diameters, even if not entirely clear from reading a simple roll specification. Un-bent flat lengths for any given sheet are a function of thickness, width, cylinder diameter, machine geometry, material yield, top roll size, operator proficiency and other factors. Rolling ratings anticipate that the plate is in motion, translating through the machine. This is called “dynamic” as opposed to the “static” pre-bending operation when the sheet is held between the rollers and one or more rolls move upward to “curl” the leading edge. Dynamic rolling mode will always allow a greater thickness to be rolled than can be bent during static pre-bending. Automation in the workplace is becoming more common as pressure increases to reduce labor costs. Most all CNC and NC controlled machines are 4 roll types. Automated controls are recommended for high volume or significantly repetitive cylinder or shell production or to roll complex shapes that are not easily reproduced by using manual machine controls. Multiple bends, variable radius bends, ovals and the like are some examples. Over automation on a roll when the production volume is not significant can be a costly mistake. Three Roll Initial Pinch or Single Initial Pinch Plate Rolls are generally for lighter capacity applications and may be electro-mechanical or hydraulic. They work by "pinching" the flat sheet between two counter-opposed rolls while the third offset roll or ‘bending roll’ moves upward to contact and then bend the sheet. When rotation of the rollers is activated, the sheet exits at a given radius. With the sheet cut to the developed length and the bending roll properly positioned; the part is rolled into a cylindrical form, where it can then be welded at the seam to produce a cylinder. The upper roll is in a fixed position; the lower pinch roll can move up/down to pinch the material. The third roll (the forming roll) is also adjustable. To remove a rolled cylinder, it must be extracted from off of the top roll. Machines are generally equipped with some type of release mechanism on the top roll to allow extraction of the cylinder. Typical methods are either a forward tilting or releasing top roll or a removable end yoke. In most applications, these machines require removal and re-insertion of the sheet in order to pre-bend both ends. They are cost effective but in contrast may be more labor intensive in a production setting. There were many large mechanical initial pinch machines built during the 1930’s, 40’s & 50’s and can be found on the used market. All have cast frames as modern alloys and welding techniques had yet to be invented. Double Pinch Plate Rolls are available from light to extremely heavy capacities and may have three or four rolls. The terminology can be confusing as these units may sometimes be referred to as ‘double pinch pyramid plate rolls’ or ‘double initial pinch plate rolls’. Both three and four roll styles have fixed position top rolls and two offset rollers or ‘lateral rolls’, one on each side. The 4 Roll styles have an additional roller directly underneath the top roll, which constantly pinches the plate during rolling. Double Pinch Rolls can pre-bend both ends of the plate without removal as is required with single pinch rolls. Three Roll machines generally require pre-bending the leading end, running the sheet through the machine to pre-bend the trailing end then switching roll rotation direction to roll the cylinder body. Four Roll Plate Rolls have a slight advantage in cycle time since t hey permit pre-bending of the leading edge, rolling the cylinder body and finishing off of the trailing edge all while rolling in the same direction. High volume products can be produced faster when using a four roll machine. Smaller machines can be mechanical but most modern machines are hydraulic and include drop end yokes for easy extraction of the work-piece. Automatic NC or CNC Controls and Four Roll Plate Rolls: Automatic cycle systems are generally used only on four roll plate rolls because there is minimal chance for slippage since the sheet is constantly pinched between the top roll and the 4th roll or “pinching roll”. Automatic controls use an encoder to track movement of the plate through the machine. If the plate slips, the bending roll movements will be out of sync with the material’s translation through the machine. Variable Geometry Three Roll Plate Rolls are not new but are gaining in popularity around the world. They are built for medium, heavy to extremely thick plate applications. The top roll moves up/down and the lower two rolls each move horizontally. This lower roll movement allows increasing the offset distance from the top roll and commensurately increasing mechanical advantage in bending. A machine of this type works well over a wide range of material thickness. By adjusting the geometry they can be used similar to single pinch, double pinch and pyramid style machines and require minimal sheet movement during the pre-bend operations. In the past these machines were commonly found in shipyards but now are being placed in general job shop and manufacturing applications. True Pyramid Machines are not generally manufactured by modern roll builders. They may be found on the used market and are more common in developing countries. They have 3 rolls, both lower rolls fixed in position with the top roll moving up/down. In general they leave very long un-bent flats and have only one or two rolls motorized in rotation. Some special application machines are still produced on a custom build basis and are mostly found in shipyards. They will have the lower two rolls spaced closely together and be of small diameter with midpoint support trunnion rollers. Two Roll Machines are designed for thin or light gauge material rolled to reasonably small diameters. They use a large diameter urethane coated pinch roller which moves up with extreme pressure against a small diameter steel top roller. A mandrel or drum, very close in OD to the desired ID of the part is fitted over the top roll. Two roll sheet rolls are extremely fast and will roll round cylinders or shells even if the blank has large cutouts, voids or holes. Since they require a mandrel for each different part diameter and material thickness they are not as versatile as some other machines. For dedicated high speed production of light gauge cylinders they can be an optimal solution. Vertical Format Plate Rolls can be of nearly any geometry, double pinch, single pinch or pyramid. Vertical rolls are most often used for rolling large diameters and can be advantageous when used in the field for storage tank production. Carell offers automated Vertical Tank Production Systems which are fed from coil stock and can include vertical sheet cutoff and automatic vertical seam welding among other options. These Systems can be used in-house or in the field and increase production output while reducing labor input Optional Equipment and Accessories are offered for most Plate Rolling Machines. The most important items to consider are hardened roll surfaces and cone rolling devices. With today’s harder materials and laser/plasma cutting techniques it is imperative to have a hardened outer surface on the rollers. Look for hardness ratings in the range of 52 to 55 Rockwell C Scale and also for the indication that the hardening process used is “induction hardening”. Hardness in the 52 to 55 RCS range will have a reasonable hardness penetration depth to provide long lasting protection against roll surface wear. Hardness exceeding 58 RCS will have a shallow penetration and a more brittle outer surface which can result in cracking or crazing. Cone rolling devices permit the operator to roll a conical shape and are standard on some machines. Some machine brands require a machine to be pre-disposed at the time of purchase if cones will be rolled in the future. This important point should not be overlooked. Lateral as well as Central Overhead Supports are optional on nearly all Double Pinch Plate Rolling Machines. Some rolls may require pre-disposition for the eventual addition of hydraulic powered supports. Overhead supports prevent lighter materials from collapsing when rolled to large diameters and must be sized according to plate thickness and shell diameter. An overhead support is not a crane and it is designed to sustain nominally only 40 to 60% of the total shell or cylinder weight. A side support can also assist in this function to prevent light materials from re-curving toward the floor if the radius is very large. Some plate rolls are designed with Extended Roll Shafts that protrude through the machine frame at the yoke end. Section or Pipe Dies can be fitted on these ‘stub’ or extended shafts. Some machines are designed with collars inside the machine frame that can be used for profile rolling but when rolling a complete 360 degree hoop it will be impossible to remove from the machine. It is also not possible to coil with inboard collars. It is not practical to anticipate rolling angle iron on a plate roll. Angle will always twist when being rolled. Plate rolls do not have outboard adjustable lateral profile guides to prevent this inherent twist. You should consider using a section rolling machine or double pinch angle roll instead for these applications. In general, section dies on plate rolls are good for bending flat bar the hard way, rods or small pipe. Roll Translation or Roll Movement Up/Down is accomplished either by using inclined linear guides or via swing arms. Direct rectilinear guides direct the thrust of the roll directly toward the top roll and have the fewest moving parts. Rectilinear guides are found on small as well as extremely high capacity rolls. Swing arm designs are not common on large machines and have more moving parts, pins, and bushings. Roll Balancing can be achieved in a variety of methods. Maintaining the bending roll or rolls parallel to the top roll is necessary in order to produce a good true cylinder. Volumetric type and electronic type balancing are the most trouble free for general job shop use. They have up to 80% fewer moving parts than swing arm balancing systems and thus significantly lower maintenance costs in the long run General Note: Roll Bending Machines are very dangerous if used carelessly. It is the responsibility of the owner to ensure the installation and proper use of point of operation safety guards or devices. Machine capacity Pre-Bending vs. Rolling Ratings Pre-bending ratings AUTOMATION Rolling ratings Three Roll Initial Pinch Double Pinch Automatic NC or CNC Controls Variable Geometry Three Roll Plate Rolls True Pyramid Machines Two Roll Machines Vertical Format Plate Rolls Optional Equipment and Accessories Cone rolling devices Lateral and Overhead Supports Extended Roll Shafts Roll Translation Roll Balancing

We manufacture and stock; tools for bending, tube rolls, pipe rolls, special tooling and custom tooling. We also carry the following brand names Parmigiani, Comac, Memoli, Omcca, Simasv, Isitan, Icaro, Offmer & More! ​ Thank you for contacting us in your search for better fabricating machinery. A representative will reach out to you as soon as possible. Innovation, Quality & Performance Backed By Decades Of Experience 251-937-0947 We Appreciate Your Interest In Our Products! Thank you for using our form Your information will be reviewed by one of our customer service specialists and someone will contact you shortly. You can also call us@ :

Making the leap into exponential growth in fabrication production, knowing how to apply & select the right automation production systems is key. We manufacture and stock tools for plate roll bending, angle rolls, tube & pipe benders, custom & special tooling, section benders and more. We also carry the following brand names - Acrotech, Air Liquid, Cansa Makina, BPR Curvatrici, CBC, Comac, Hyllus, Icaro, Isitan, Lucas, Macri, Memoli, Ofmer, OMCCA, Omera, Parmigiani, Pedrick, Sahinler, and Simasv. We manufacture and stock tools for plate roll bending, angle rolls, tube & pipe benders, custom & special tooling, section benders and more. We also carry the following brand names - Acrotech, Air Liquid, Cansa Makina, BPR Curvatrici, CBC, Comac, Hyllus, Icaro, Isitan, Lucas, Macri, Memoli, Ofmer, OMCCA, Omera, Parmigiani, Pedrick, Sahinler, and Simasv. Automation Production Systems Evolving Into Automation Production Systems For small businesses making the manufacturing leap into exponential growth in fabrication production, understanding how to apply and select the right automation production systems is key. Capital investment is one of the biggest investment decisions a small business can make for large-step growth, so it’s essential to choose right the first time. The wrong equipment can seriously impact profit margins as well as limit the scale of service a fabricator can offer its clientele. Carell Corporation provides a large portfolio of automation production systems for growing companies, handling equipment needs for manufacturing for everyone from startups and small business to medium and large-size plant companies. With a high-performance selection available in multiple fabrication categories, Carell insures its customers are guided to the right equipment and tooling systems they need at every stage of their growth track. And, the automation system series that are available provide for all types of situations, including small footprint needs as well. Getting into the Accuracy of CNC Controls When it’s time to start moving in high accuracy fabrication, particularly of metal end product goods, CNC controls are essential. They can be guided manually or with automation programs (more popular), coupling with high production fabrication runs and demands. And because the accuracy potential is so high on the production side, companies can open up their possibilities for additional markets and sales as a result, especially into niche markets where specs are down to the millimeters or smaller for order fulfillment. The high quality CNC system Carell Corporation can make available also come with extensive guidance, training and capital equipment support through Carell for long investment life and profit margin turnaround in maintained production levels. With all these wins, its surprising more fabricators haven’t instituted CNC controls as fast as possible, especially with Carell Corporation’s available support.

Carell was founded to fill a need for tough, dependable plate rolls, angle rolls, pipe benders, horizontal presses and various other benders by providing the broadest range of high quality bending machines, options and tooling to match any budget and application. We manufacture and stock; tools for bending, tube rolls, pipe rolls, special tooling and custom tooling. We also carry the following brand names Parmigiani, Comac, Memoli, Omcca, Simasv, Isitan, Icaro, Offmer & More! ​ A Simple Philosophy.. . Offer The Best Roll Benders... ...and back them up with the Best Warranty in the Industry to prove it! About Us Google Maps Find Us On CONTACT US Carell Corporation was founded to fill a need... for tough, dependable Plate Rolls, Angle Rolls Tube & Pipe Benders and other fabricating machines capable of working day after day with minimum down time. Our quest in worldwide manufacturing solutions has produced proven results that f rom the best materials inside and out, come the strongest machines ever built. All our equipment is designed and tested in the field to offer unparalleled performance under the toughest conditions. It's no coincidence that the strongest machines come with the strongest warranty ever written! Every specification is carefully thought out to produce the best end product possible to meet the demands of today's industry. Located conveniently in Stapleton, Alabama at the juncture of major east/west and north/south interstate arteries and the Port of Mobile. Carell Corporation inventories and supports the broadest range of bending machines, tooling and options to match any budget or application. Our Team of Factory Trained Technicians, Application Engineers, Tooling Designers and Support Staff provide you with solutions for the life of your machine. Carell’s Testing Facility and CNC Machine Shop produces Custom Rolls and Tooling In-house to accomplish the most demanding of roll bending applications. We are Solution Oriented and have an extensive stock of machines- tooling-parts ready to ship to your location. No Shortcuts… every specification is carefully thought out to produce the best end product possible and.... backed by an UNMATCHED Warranty and Professional Customer Service! 100% TOTAL PARTS COVERAGE We Back Our Benders with UNMATCHED Warranties! 100% TOTAL PARTS COVERAGE - Including OEM components! Warranty periods vary from 12 to 24 months depending on the bending machine model. Parts are FOB Eagle Bending Machines for units used under normal indoor working conditions. All warranties are conditional, exclude labor and are subject to limitations. Please contact us for details.

STANDARD AND CUSTOM TOOLING Carell manufactures tooling in-house in our CNC Machine Shop for rapid turn-around and enhanced quality control for Angle Rolls,Tube & Pipe Rolls, Special Profiles, Supports, Cap Rail, Half Pipe, Coils, Traction & "V" Groove Tooling. STANDARD AND CUSTOM TOOLING Carell manufactures tooling in-house in our CNC Machine Shop for rapid turn-around and enhanced quality control" TUBE & PIPE ROLLS Most Common Tube OD & Pipe Sizes In Stock. Hardened, Solid Tool Steel. Any Size Can be Made. Specify Smooth or Knurled. Also available in Polymer Material for Delicate Finishes. CUSTOM TOOLING FOR SPECIAL PROFILES We can produce special tooling for a variety of machine makes, types and models. Forward drawings of your profiles and machine information for a quote TOOLING AND SUPPORTS FOR HALF PIPES & COILS 3000 Series Machines can be equipped with tooling for producing half tubes from strip & supports for coiling. Overhead supports (man. or hydraulic) may have coil diameter & pitch adjustment or be interlocked to NC/CNC controls. TRACTION TOOLING BEAMS BENT HARD WAY Larger capacity 3000 Series Angle Rolls can be fitted with traction tooling and rolls for effective rolling of beams as well as channels bent in the X-X axis or 'Hard Way" SECTION DIES FOR PLATE ROLLS For Plate Bending Machines with extended shafts, roll sets for profiles and tube or pipe can produced. Call to discuss capacities and pricing. "V" GROOVE ROLLS Roll Bar Stock and Square Tube on a 45° angle to Create a Unique Look. Available for all Models in both Smooth and Knurled. Made of Solid, Hardened, Tool Steel here at Carell Corp. CUSTOM ROLLS We manufacture Tooling In-House To Roll a Wide Range of Custom And Special Profile Shapes in a Variety of Material Types. CAP RAIL SOLUTION A For Aluminum & Brass Cap Profiles. Three Fully Contoured Polymer Rolls. Six Steel Shoulder Plates May be Required. Call for Capacities CAP RAIL SOLUTION B The Most Economical Cap Solution. 3 Semi-Contoured, Hardened Steel Inserts to Match the Cap. Most Commonly Used With Standard Tooling. Furnished Smooth. CAP RAIL SOLUTION C Best Suited For Production Jobs. 3 Fully Contoured, Hardened Steel Rolls Built To Match Your Cap Sample. Furnished Smooth. REPLACEMENT COMPONENTS Lost a piece or need a smooth surface component for working with soft or delicate material? We stock Smooth and Knurled standard roll components for all machines. CUSTOM TOOLING Send Drawings and/or Samples For Pricing on Custom Rolls And Accessories. Carell also can create custom tooling for other metal bending machines such as; PARMIGIANI, COMAC, FAMAR, ICARO, MEMOLI, CBC, SIMASV and more… Carell Corporation can handle your tooling/rolling needs for aluminum extrusions, satin/polished/pre-painted finished sections, steel/brass/aluminum decorative hand rails, oversized 'U' and 'C' shapes, overwide flats, half tube production from flats, hard way beam and channel rolling to name just a few.