100-roll Hydraulic Leveling Machine

Product Introduction

In the field of high-end precision manufacturing, the flatness of metal sheets directly determines the assembly accuracy and fatigue life of the final product. This 100-roll hydraulic leveling machine is not merely a simple “flattening” tool, but rather a stress-relief system based on the theory of elastic-plastic deformation. It is specifically designed to address issues such as uneven internal stress, waviness, and edge warping in metal sheets resulting from rolling, cutting, or heat treatment. Through precise hydraulic drive and multi-roll staggered arrangement technology, it imparts a perfect geometric form to the raw material.

Core Technical Principles:

This equipment abandons traditional mechanical rigid pressing in favor of an advanced hydraulic servo control system. Its core logic lies in utilizing the material’s inherent plasticity:

• Repeated Alternating Bending: As the sheet passes through the upper and lower Φ100 working rolls arranged in an interlaced pattern, it is subjected to continuous, decreasing alternating bending moments.

• Stress Release and Reorganization: Under powerful hydraulic pressure, the internal fibers of the sheet are forcibly stretched and compressed, causing the stress to exceed the material’s yield point. Through multiple smooth transitions between “high curvature” and “low curvature,” the originally disordered residual stresses within the sheet are thoroughly dispersed and rebalanced, thereby achieving absolute flatness on a macroscopic scale.

• Precision Advantages of the 100-mm Roll Diameter: The optimized design for 100-mm rolls significantly reduces the roll pitch while ensuring sufficient leveling torque. This means the sheet undergoes a greater number of minute deformations per unit length, greatly enhancing leveling precision. It is particularly suitable for medium- and heavy-gauge plates and high-strength steels that demand extremely high surface quality.

Technical Specifications

Key Structural and Technical Highlights

Four-roll/Six-roll Roll Train Configuration:

High-rigidity support rolls (or intermediate rolls) are positioned on the outer side of the working rolls, forming a multi-support structure. This design effectively counteracts the significant deflection generated during the leveling process, ensuring lateral uniformity of the roll gap and eliminating phenomena such as “central waviness” or “edge wrinkling” in the sheet.

Intelligent Hydraulic Roll Pressure System:

The upper roll train is driven by independent hydraulic cylinders, which, in conjunction with high-precision displacement sensors, enable micrometer-level adjustment of roll pressure. The system features overload protection; it automatically relieves pressure upon encountering unexpected hard objects or excessively thick material, ensuring equipment safety.

Integrally Prestressed Frame:

Featuring a monolithic, enclosed frame design with optimally arranged internal stiffeners and pre-stressed reinforcement, the machine maintains exceptional structural rigidity even when subjected to hundreds of tons of leveling force, minimizing frame deformation.

Digital Closed-Loop Control:

Integrated with a PLC (Programmable Logic Controller) and a touchscreen HMI (Human-Machine Interface), operators can preset process parameters for different materials and thicknesses to achieve “one-touch” leveling. Some high-end configurations can be equipped with a laser leveling sensor, which provides real-time feedback on sheet flatness and automatically adjusts the roll gap, achieving true closed-loop control.

Applications

This equipment is widely used in industries with stringent flatness requirements:

Precision Machinery Manufacturing: For pre-processing raw materials used in automotive components and aerospace structural parts.

Heavy Equipment: For leveling thick plates used in ship decks, construction machinery chassis, and bridge steel structures.