Benefits about Tension Leveller

tension leveller

Tension leveller is a machine that stretches plastic strips by applying tension and continuous bending to improve their shape.

Two tension rolls at the inlet and outlet stabilize tension and reduce fluctuations. The tension is increased by the roll group.

The straightening unit has two rows of bending components and balancing rollers. In the first stage, the strip undergoes alternating deformation to evenly distribute residual deformation, which is fully corrected in the second stage, improving the strip’s shape and mechanical properties.

Tension leveller is used to eliminate all kinds of three-dimensional plate shape defects such as bilateral wave, unilateral wave, middle wave, two-rib wave, warping, buckling and potential bad plate shape.

In the process of calendaring strip, the above-mentioned plate shape defects will be occurred in the coiled strip due to bad roll shape and roll gap shape. These defects are caused by the uneven longitudinal extension of the rolled piece in width direction and the disorder of rolling stress. In order to eliminate the bad shape of the coiled strip and make the internal stress tend to be uniform, the coiled strip needs to be corrected.

The structure of tension leveler is two bending and two leveling single drive type,the parts as below,

No.	Name	Drawing no.	Qty.	Remarks
1	Frame		1 set
2	Φ30 bottom bending roll units		2 sets
3	Φ30 top bending roll units		2 sets
4	Locking device		2 sets
5	Φ200 top straightening roll units		4 sets
6	Bottom lifting device		1set
7	Φ50 anti-horizontal bending roll units		1set
8	Φ70 anti-vertical bending roll units		1set
9	Roll change device		1set

Scope of supply

Mechanical part: Main machine and roll change device of double bending and double straightening machine (excl. anchor bolt, valve table and guide rail);

Electrical part:the electrical wiring on the host is connected to the junction box of the host;

Hydraulic part: Include only the hydraulic pipe, and leave the interface on the transmission side;

Packing

Tension Leveller with Vacuum-packed and wooden case packing.

Application of Tension Leveller

Extensively used in the field of Iron and steel 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.
Popular use for Rail transit.
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.