The description of tension leveler machine

tension leveler machine can effectively the plate shape of the strip, and has been widely used and developed in stainless strip processing.

The key point of flatness of the strip is the leveling machine.When the strip enter into leveler, the work roll of the leveler is pre-adjusted according to the thickness of the incoming strip and the straightness of the strip.

The compose of tension leveler machine

This machine is composed of the main parts and the hydraulic servo system.

Main parts: It is composed of frame assembly, pressing mechanism, swing mechanism, upper roll device, lower roll device and its sensor device.

The frame is an open structure, which is characterised by good stress, strong rigidity and beautiful surface. The frame is made of Q235A steel plate, continuously welded after plasma blanking, annealed by the electric furnace as a whole after welding, and processed on a ten-meter CNC boring and milling machine;

The opening and closing of the frame is positioned by a tapered pin, one end of the pin is the fixed end, and the other end of the pin is pushed and positioned by the oil cylinder before it can be induced by the proximity switch to ensure safety;

The depress mechanism is driven by the 3KW motor and reducer to the worm in the worm gear reducer to rotate the worm gear, the depressed screw is installed in the worm gear, the depressed nut is fixed on the worm gear, and the depressed screw does not rotate but drives the upper roller system to move up and down.

The swing mechanism is driven by the motor and the reducer to drive the eccentric shaft, and the rotation of the eccentric shaft makes the upper roller system mounting frame produce a deflection angle.

Incoming Material Parameter:

material： Semi-hard, hard 200 series, 300 series, 400 series, etc

Performance: Yield limit: ：205 MPa≤σs≤1350 MPa

width： 600～1060 mm

Thickness： 0.1～0.6 mm

Work roll device:

It consists of 23 upper and lower work rolls, 25 intermediate rolls and back-up rollers. The work rolls are arranged in a staggered manner, with 11 in the upper row and 12 in the lower row.

The cylinder adjustment crown (11 sections can be adjusted separately), the diameter of the work roll ф16mm, and the roller bearings are all imported INA or FAG brands.

Lower back up roll adjustment mechanism:

Adopt eleven groups of servo-hydraulic cylinder adjustment, push by hydraulic cylinder, make the inclined block that is installed on the frame move, so that the lower back-up roller system up and down moves up and down to or away from the working position to carry out convexity adjustment, and each group can carry out convexity adjustment separately.

Straightening roll cassettes: including a set of Φ16mm straightening roll cassettes, each set of straightening roll cassettes contains a group of straightening roller systems on the upper and lower. The length of the roll surface of the upper and lower sets of roller systems is different, and its composition is shown in the following table:

Work roll, intermediate roll material: Cr12MoV (surface quenching treatment HRC64~66, quenching depth 2~2.5mm). The upper and lower roller boxes can be pulled out at the same time.

Application of Tension Leveller machine

Extensively used in the field of stainless strip manufacturing.
Steel manufacturing is one of the main application areas of tension leveling machines, which are usually used in casting, rolling, drawing, straightening and other links. In the construction of high-speed railway, the tension leveler is also very important.
In addition to high-speed railways, subways, trams, airport integrated transportation hubs and other transportation construction all need to use tension straighteners for the processing of metal sheets.
Widely utilized in Automobile manufacturing field.
Automobile manufacturing is also one of the main application areas of tension leveling machines.Tension levelers can be used to process car bodies, doors, roofs and other components.
Used in the entertainment industry home appliance manufacturing like Televisions, refrigerators, air conditioners and other household appliances also need tension leveling machines for plate processing in the manufacturing and production process.

FAQ

Tension leveler FAQ with answer

1. What is a tension leveler?
A tension leveler is a machine used in the metal processing industry to improve the flatness and shape of metal sheets or strips by applying controlled tension and bending.

2. How does a tension leveler work?
Tension levelers work by pulling metal sheets through a series of rolls while applying tension. This process elongates and flattens the material, correcting any shape defects.

3. What types of materials can be processed using a tension leveler?
Tension levelers are typically used for processing steel, aluminum, copper, and other metal alloys in sheet or strip form.

4. What are the benefits of using a tension leveler?

Improved flatness and shape control of metal sheets.
Reduction of residual stresses within the material.
Enhanced surface quality and appearance.
Enables downstream processes like cutting, stamping, and welding.
5. What factors should be considered when choosing a tension leveler?

Material thickness and width capacity.
Required level of flatness and shape tolerance.
Speed and throughput requirements.
Integration with existing production lines.
6. How do tension levelers differ from roller levelers?
Tension levelers use tension to elongate and flatten materials, whereas roller levelers use a series of rollers to mechanically flatten materials without applying tension.

7. What maintenance is required for a tension leveler?
Regular maintenance includes lubrication of rolls and bearings, inspection of hydraulic systems (if applicable), and periodic adjustment of tension settings.

8. How can I optimize the performance of a tension leveler?

Ensure proper setup and calibration according to material specifications.
Monitor tension levels and roller alignments regularly.
Train operators on correct operating procedures and safety protocols.
9. What safety precautions should be followed when operating a tension leveler?
Operators should be trained in safe handling procedures, wear appropriate personal protective equipment (PPE), and follow lockout/tagout procedures during maintenance.

10. Can tension levelers be customized for specific applications?
Yes, tension levelers can be customized with different roll configurations, tension control systems, and automation features to meet specific processing requirements.

Parameters and requirements need to offer for making a tension leveler:1. Material and Processing Requirements: Metal Type: Specific types of metals to be processed, such as steel, stainless steel, aluminum alloys, copper, etc. Sheet or Strip Specifications: Including maximum width and thickness range. Surface Finish Requirements: Such as flatness (straightness requirements), surface quality (e.g., scratches, oxide layers), mirror finish, etc.2. Production Capacity and Efficiency Requirements: Production Rate: Number of sheets or strips processed per hour. Automation Needs: Requirement for high automation control, such as automatic tension adjustment, thickness control, etc.3. Equipment Functionality and Features: Tension Control: Requirements for the tension control system, including precision, stability, etc. Shape Control: Requirements for flatness and shape correction, such as straightness and waviness limits. Adjustability: Ability of the equipment to adjust for different materials and specifications.4. Environmental and Safety Requirements: Operating Environment: Environmental conditions for equipment installation, such as temperature, humidity requirements. Safety Standards: Compliance with safety standards and occupational safety requirements, including safety measures, operator training, etc.5. Customization and Service Requirements: Customization Options: Specific customization requirements, such as color, coating, machine appearance design, etc. After-sales Service: Requirements for reliable after-sales service and support, including warranty period, technical support, spare parts availability, etc.