80-roll Hydraulic Leveling Machine

Product Introduction

The 80-roll hydraulic leveling machine is custom-designed for plates with thicknesses ranging from 2.0 to 10 mm. Its high-pressure hydraulic system delivers high torque, enabling it to easily correct residual stresses and deformations in thick plates resulting from rolling, cutting, and welding. It is suitable for high-strength materials such as carbon steel, wear-resistant plates, and stainless steel plates. The equipment features a staggered multi-roll arrangement and a dense support structure, providing excellent roll bending resistance and eliminating roll deformation during the leveling of thick plates. Closed-loop hydraulic control ensures precise and stable pressure and roll gap, resulting in high leveling accuracy and excellent consistency. The machine features a robust and durable structure, suitable for heavy-duty processing applications. It can be integrated with leveling lines, shearing machines, and other equipment to form a coordinated production line. Equipped with overload protection and an oil cooling system, it operates reliably under heavy loads for extended periods. The control panel features a digital display for intuitive and convenient parameter adjustment, and maintenance procedures are standardized, making it ideal for large-scale sheet metal, steel structure, and agricultural machinery component manufacturers.

Product Advantages:

Roller System Rigidity and Stability:

• Utilizes Φ80mm solid forged work rollers combined with a multi-layer dense support structure. When leveling medium-to-thick plates and high-strength alloys, roller deflection is minimal, ensuring no deformation during long-term operation and uniform force distribution across the entire sheet width.

Hydraulic Independent Pressure Control Technology:

• The upper roll features zoned hydraulic servo control, allowing continuous adjustment of individual roll pressure and achieving a leveling accuracy of ±0.01 mm. The system automatically and flexibly relieves pressure when encountering weld seams or localized thickness variations, preventing indentations and damage from excessive pressure.

Low-noise, energy-efficient, and stable operation, compatible with continuous production lines:

• Utilizes hydraulic servo + universal joint drive, with noise levels ≤72 dB(A), making it environmentally friendly for the workshop; the energy-saving design of the hydraulic accumulator reduces power consumption by 30% compared to traditional mechanical models; continuous operation for 8 hours without temperature drift, enabling integration with automated production lines such as uncoiling, shearing, and laminating.

Anti-deflection rigidity and lateral precision locking:

• The 80-mm roll diameter design is specifically engineered to address the “roll shaft deflection” challenge in wide-width sheet leveling. When processing sheets wider than 2 meters, the immense reaction force can easily cause thin roll shafts to bend and deform, resulting in sheet bulging in the center. The 80-mm roll diameter significantly increases the sectional moment of inertia. Combined with a dense system of support rolls, this ensures the straightness of the roll shaft under heavy loads, effectively eliminating the “central waviness” defect in the sheet’s transverse direction and guaranteeing the overall flatness of ultra-wide sheets.

Technical Specifications

Operating Guide for the 80-Roll Hydraulic Leveling Machine

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.

Pre-Startup Inspection and Preparation

• Before connecting the main power supply, it is essential to verify the equipment’s basic operating conditions, which is particularly critical for heavy-duty machinery. First, inspect the lubrication system to confirm that the grease pump pressure meets the standard (typically indicated by a red dot or pressure gauge), and ensure the gearbox oil level is at the midpoint of the sight glass, as 80-roll machines are highly sensitive to frictional heat under heavy loads. Second, inspect the roller surfaces. Clean them with a clean cloth to ensure there is no weld slag, scale, or metal debris. These hard particles can permanently damage the rollers and cause indentations on the sheet under high pressure. Finally, verify electrical safety by testing whether the emergency stop button resets promptly and whether the safety guards are locked in place, ensuring the equipment is in a “fault-free” standby state.

Logic for Setting Initial Parameters

• For 80-roll models, the initial roll gap setting should not be based solely on empirical estimates but must take into account both sheet thickness and material strength. The general setting principle is “wide at the inlet, narrow in the middle, and even at the outlet.” It is recommended to set the inlet roll gap to the sheet thickness plus 0.2 to 0.5 millimeters to facilitate smooth sheet entry; The roll gap in the intermediate leveling zone should be slightly reduced based on the material’s yield strength, typically set between 95% and 98% of the sheet thickness (i.e., slight reduction); the roll gap on the exit side should be restored to the sheet thickness or slightly larger to release stress. For high-strength steel, the reduction amount of the intermediate rolls must be appropriately increased, but the pressure readings of the hydraulic system must be strictly monitored to avoid exceeding the rated load.

Trial Flattening and Dynamic Fine-Tuning

• Trial flattening must be conducted before formal mass production. Select a representative test plate and feed it in intermittently at low speed (below 50% of the rated speed). Observing the plate’s shape after discharge is critical: if the plate exhibits reverse camber, it indicates excessive intermediate reduction, requiring a slight adjustment of the intermediate roll handwheel or a reduction in hydraulic pressure; If the sheet retains its original warping, this indicates insufficient flattening force, requiring a symmetrical, slight reduction in the roll gap. For 80-roll equipment, adjustments should follow the “small increments, multiple times” principle, with each adjustment recommended to be within 0.1 mm, until the sheet achieves the desired flatness.

Key Monitoring Points During Production

• During batch leveling, operators must pay close attention to sheet misalignment and unusual noises from the equipment. Since 80-roll equipment processes wider sheets, it is essential to ensure the sheet is perpendicular to the roll train during feeding to prevent “sickle bending” or jamming. It is strictly prohibited to adjust the roll gap or switch between forward and reverse rotation while the equipment is running; these operations must be performed only when the machine is shut down. Additionally, after processing 5 to 10 sheets, one sheet should be randomly selected for flatness inspection, and the sheet surface should be examined for periodic indentations. If a dull thudding sound is heard from the gearbox or bearings, immediately press the emergency stop button and check for loose bolts or foreign objects.

Shutdown and Maintenance Procedures

• After completing operations, do not disconnect the power supply immediately. First, stop the feed and wait until all remaining sheets have passed through before turning off the main motor. Subsequently, use an air gun to remove dust from the roller surfaces and the sheet support frame, and wipe the roller surfaces with a wrung-out damp cloth to prevent rust. For the 80-roll model, it is recommended to regularly (e.g., weekly) record the oil temperature and pressure of the hydraulic station and inspect the wear on the support rolls. Finally, complete the operation log, detailing the material thickness processed during the shift, the roll gap settings, and any abnormalities, to provide data support for the next shift’s operations.