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The 60-roll hydraulic leveling machine is designed for medium-to-heavy gauge sheets ranging from 1.0 to 8 mm. Its high-flow hydraulic system delivers ample leveling force, enabling it to process materials such as hot-rolled sheets, checkered plates, and high-strength low-alloy steel sheets, effectively correcting significant deformation resulting from rough machining. The optimized ratio of roll diameter to roll spacing ensures strong gripping capability and minimizes sheet slippage. Combined with hydraulic roll compensation technology, this guarantees uniform leveling across the entire width of the sheet, with flatness controlled within 0.05 mm/m². Equipped with a high-power drive system, the machine offers stable and adjustable feed speeds, making it suitable for heavy-duty sheet metal, construction machinery components, and small steel structure parts. The machine body is constructed from thickened steel plates welded into shape, ensuring exceptional rigidity and resistance to deformation. Comprehensive safety interlock devices guarantee operational safety, enabling long-term continuous operation. With a long service life for wear parts and low overall operating costs, this model is the workhorse for medium-to-heavy plate leveling.
To address the challenge of hot-rolled internal stresses in 1.0–4.0 mm medium-to-thick stainless steel sheets, the equipment innovatively employs a solution combining 60 mm large-diameter rolls with 300-ton hydraulic pressure. By precisely controlling the roll system to perform penetrating leveling on the sheet, it effectively acts on the core of the material, thoroughly eliminating the uneven internal stresses generated during the hot-rolling process. After processing with this equipment, deformation of construction machinery components during subsequent welding operations is significantly reduced by 60%, substantially improving the dimensional stability and assembly accuracy of structural parts.
To address the common “sickle-bend” defect in cut-to-length plates, the equipment is equipped with a high-precision edge sensor system capable of real-time detection of deviations in the plate’s edge profile. Based on intelligent algorithm analysis, the system automatically applies asymmetric pressure for targeted correction, improving sheet straightness accuracy to ±0.1 mm. This fully meets the high standards required for laser cutting and precision machining of structural components, effectively reducing scrap rates in subsequent processes.
To minimize equipment downtime for maintenance, an innovative modular roller cartridge design has been adopted. Replacing worn rollers requires no disassembly of the equipment frame; the entire roller system can be replaced in just 20 minutes, significantly shortening maintenance cycles. This design increases production line uptime to over 95%, effectively reducing production losses caused by equipment maintenance and improving overall capacity utilization.
Width of standard series | 600 | 1000 | 1300 | 1600 | 1900 | 2100 |
|---|---|---|---|---|---|---|
Diameter of leveling roller | 60 | 60 | 60 | 60 | 60 | 60 |
Number of leveling rollers | 21 | 21 | 21 | 21 | 21 | 21 |
The shortest workpiece length for flattening Lmin (mm) | Lmin=130 | Lmin=130 | Lmin=130 | Lmin=130 | Lmin=130 | Lmin=130 |
Nominal thickness of leveling material T (mm) | 1.0-8.0 | 1.0-8.0 | 1.0-8.0 | 1.0-8.0 | 1.0-8.0 | 1.0-8.0 |
Maximum thickness of flattening material Tmax (mm) | Tmax=15 | Tmax=15 | Tmax=15 | Tmax=15 | Tmax=15 | Tmax=15 |
Leveling accuracy | The parameters are calculated according to the material Q235/yield strength 235MPa, and the length and width are detected within 1m | |||||
0.01-0.05mm | 0.01-0.05mm | 0.01-0.05mm | 0.01-0.05mm | 0.01-0.05mm | 0.01-0.05mm | |
Straightening line speed (m/min) | Speed adjustable at 1-10m/min | |||||
voltage | AC three-phase 380V | |||||
Optional Accessories | 1.Pulling out the flattening roller downwards (convenient for roller quick change and surface cleaning) | 4.Four/six times leveling roller | 7.Number of leveling rollers | |||
2.Pulling out the leveling roller (convenient for roller quick change and surface cleaning) | 5.Automatic loading/unloading manipulator/palletizing robot | 8.Uncoiler - Hydraulic/Mechanical Cutting Line | ||||
3.Pulling out the roller up and down (convenient for roller quick change and surface cleaning) | 6.Feeding and discharging roller assembly line: with/without power | 9.Uncoiler - laser cutting blanking line | ||||
Customized requirements | Customer customization requirements are acceptable | |||||
Remarks | Straighten the pressing gap of materials, input relevant parameters through the touch screen, and the equipment will automatically adjust. | |||||
Can this machine correct H-beams that have warped after welding?
It should be noted that the standard 60-ton hydraulic leveling machine is primarily designed to correct the flatness of sheet metal. For welding deformation in the flanges of H-beams, a specialized H-beam straightening machine is typically required. This specialized equipment uses a die formed by upper and lower straightening rolls to apply bending forces in specific directions to the flanges to achieve the straightening objective. Although both processes involve plastic deformation in principle, the equipment structures and application scenarios differ.
Why do periodic indentations appear on the sheet surface after leveling?
This is usually caused by one of the following two reasons:
Roll surface contamination: Metal debris, welding slag, or other hard particles are adhering to the surface of the leveling rolls. Under high pressure, these foreign objects are pressed into the sheet surface, forming periodic indentations that correspond to the circumference of the roll.
Roll surface damage: The leveling rolls themselves have scratches, flaking, or fatigue cracks.
Solution: Immediately shut down the machine and clean the roll surface with a clean cloth or specialized tool. If the problem persists after cleaning, inspect the roll surface for physical damage and grind or replace the rolls as necessary.
Which components require the most attention during routine maintenance?
To ensure long-term stable operation of the equipment, routine maintenance should focus on:
Leveling rolls: Clean the roll surfaces after each shift and regularly inspect them for scratches or wear.
Lubrication system: Ensure that all bearings and gearboxes have sufficient lubricating grease and that oil lines are unobstructed.
Hydraulic system: Regularly check oil levels and quality, keep the system clean, and prevent leaks.
Electrical system: Ensure proper ventilation of the electrical cabinet and clean sensor lenses to prevent dust from interfering with signals.
Does the leveling process cause the sheet metal to harden or result in work hardening?
The essence of leveling is to eliminate residual stress within the sheet metal through repeated, small-amplitude alternating bending, rather than inducing cold work hardening through large deformations. By precisely controlling the reduction ratio and number of bends, the equipment keeps the plastic deformation of the sheet metal at a low level (typically less than 2%); therefore, it does not significantly alter the material’s hardness or mechanical properties. Its core objective is “stress relief” rather than “altering the material properties.”
