120-roll Hydraulic Leveling Machine

Product Introduction

In the fields of heavy equipment manufacturing and precision sheet metal processing, the 120-roll hydraulic leveling machine is more than just a piece of equipment; it is the ultimate solution for eliminating internal stresses in metal sheets. Unlike traditional mechanical leveling methods, this machine is specifically designed to handle sheets with high yield strength, significant thickness, and severe residual stresses. By leveraging the high-rigidity contact advantages of its large-diameter roller system, combined with the flexible pressure control of the hydraulic system, it performs a deep “microstructural reconstruction” of the metal sheet. This process completely eliminates defects such as waviness, sickle bend, and edge warping, imparting the material with perfect geometric form and a stable internal structure.

Core Technology Analysis:

The core of this equipment lies in the key parameter “120”—specifically, the 120mm diameter of the working roll. This design is not merely a simple increase in size, but a profound innovation based on mechanical principles:

High-rigidity contact and resistance to deflection:

• Compared to equipment with smaller roll diameters, the 120mm working roll possesses an extremely high section moment of inertia. When processing thick plates (e.g., 4mm–40mm) or high-strength steel, the roller shaft itself exhibits virtually no flexural deformation. This ensures that the pressure applied to the plate is uniformly distributed across the entire width of the roller surface, effectively preventing the “denting in the center and wrinkling at the edges” phenomenon common in traditional equipment, and guaranteeing consistent transverse flatness of the plate.

Deep Stress Relief:

• The large-diameter rollers, driven by high-torque hydraulic motors, generate a larger contact area and greater penetration depth. As the sheet passes through the staggered upper and lower roller systems, its internal fiber layers are subjected to intense alternating tensile and compressive forces. These forces penetrate deep into the core of the sheet, completely disrupting the residual stress balance between crystal lattices and inducing plastic flow, thereby achieving comprehensive flattening from the surface to the core.

Progressive Curvature Decay Technology:

• The equipment employs a multi-roll staggered layout (typically 9-roll, 15-roll, or 19-roll configurations) to form a deformation channel with gradually decreasing curvature. The sheet undergoes a large-deformation “reverse bend” at the inlet end, followed by progressively reduced elastic-plastic deformation through subsequent roll sets, ultimately achieving a nearly zero-curvature, straightened state at the outlet end.

Technical Specifications

Key Structures and Technical Highlights

As a core piece of equipment for processing medium- and heavy-gauge plates and high-strength steel, the 80-roll hydraulic leveling machine operates on a logic that differs significantly from that of smaller, precision leveling machines. Since this model is primarily designed for thicker, wider, or higher-strength plates, the key to operation lies in “utilizing rigidity” and “precisely controlling the reduction amount” to prevent equipment overload or surface damage to the plates.

Monolithic Prestressed Frame:

• Abandoning the traditional split-type structure, this system employs a closed-frame design cast as a single unit or welded from high-strength steel plates, with gusset plate layouts optimized via finite element analysis. Internal prestressing is applied to the frame, ensuring micron-level structural stability even when subjected to hundreds or even thousands of tons of leveling force, thereby eliminating the impact of frame deformation on leveling accuracy.

Hydraulic Servo Roll-Down System:

• The upper row of work rolls is driven by independent high-precision hydraulic cylinders, working in conjunction with displacement and pressure sensors to form a closed-loop control system. Operators can precisely set the roll-down amount for each roll position based on the material, thickness, and deformation level of the sheet. The system features automatic pressure maintenance and overload protection functions, ensuring constant pressure during continuous operation and safeguarding equipment safety.

Intelligent Lubrication and Cooling System:

• To address the frictional heat generated by large-diameter rollers operating at high speeds, the equipment is equipped with a centralized automatic lubrication system and roller surface cooling spray devices. This not only extends the service life of bearings and roller surfaces but also effectively prevents changes in roller gap caused by thermal expansion, ensuring precision stability during prolonged operation.

Digital Human-Machine Interface:

• Integrated PLC (Programmable Logic Controller) and industrial touchscreen. The system includes a built-in database of leveling processes for various common materials (such as Q235, Q345, stainless steel, and aluminum alloy), supporting “one-click recall.” It also features automatic fault diagnosis, displaying real-time hydraulic system pressure, oil temperature, and roll gap status, significantly reducing reliance on operator experience.

Typical Applications

Thanks to its powerful leveling capabilities, this series of equipment is widely used in heavy industry sectors with stringent requirements for sheet flatness:

Construction and Mining Machinery: Used for pre-treatment of thick plate structural components such as excavator booms, crane undercarriages, and mine car bodies to eliminate internal stresses prior to welding and prevent post-welding deformation.

Shipbuilding and Offshore Engineering: For leveling extra-long and extra-wide steel plates used in ship decks and bulkheads, addressing the natural curvature of hot-rolled coils after uncoiling.

Pressure Vessel and Boiler Manufacturing: Ensures the absolute flatness of plate assemblies for vessel shells, improves alignment accuracy, and reduces weld defects.