Manual Leveling Machine (80mm Roll Diameter)

Product Introduction

The 80-mm-diameter manual leveling machine is specifically designed for leveling medium- to heavy-gauge sheet metal. It features a solid roller shaft structure with a larger diameter, providing enhanced rigidity. When processing metal sheets with internal stresses, it effectively reduces springback and waviness, ensuring consistent leveling results. The machine features manual precision adjustment, with roller gap controlled via a handwheel and dial. Operation is intuitive and reliable, requiring no electrical control system, making it ideal for flexible processing of small batches and multiple specifications of workpieces. The equipment is suitable for various sheet materials, including stainless steel, carbon steel, and aluminum-copper alloys, and performs particularly well with thicker, higher-hardness workpieces. The reinforced roller shafts resist deformation, ensuring long-lasting machining precision. The machine features a compact design with a small footprint and simple maintenance, making it suitable for workshop workstations, mold processing, and hardware manufacturing applications. Without the need for automated production lines, it delivers reliable flatness correction at a lower operating cost, balancing practicality and durability.

Product Features

1. Features 80mm reinforced solid rollers, significantly enhancing rigidity and bending resistance. When processing medium-to-thick sheets, the rollers are less prone to bending or deflection, offering superior leveling stability compared to conventional models with smaller roller diameters.

2. The roller gap adjustment mechanism features precise graduations, making fine-tuning more intuitive. It allows for segment-by-segment fine correction tailored to different sheet thicknesses, providing greater adaptability for sheets with localized stress deformation.

3. The machine features a robust yet compact design, requiring minimal floor space and offering flexible mobility. It is suitable for various applications, including mold shops, small-batch production, and maintenance workstations.

4. Maintenance costs are low; routine lubrication and cleaning are sufficient to ensure long-term, stable operation. With few wear parts and simple replacement procedures, the machine offers greater cost-effectiveness over the long term.

Technical Specifications

Manual Adjustment Features

Unlike traditional CNC leveling machines, this model employs a fully manual, worm-gear-driven four-point balanced fine-adjustment mechanism for roller gap adjustment. The operator rotates a handwheel to drive the worm gear mechanism, moving the movable crossbeam up and down to precisely control the gap between the leveling roll and the lower roll. The adjustment mechanism is equipped with a dial gauge that displays the adjustment value in real time, with a reading accuracy of up to 0.1 mm. Operators can make fine adjustments at any time based on the sheet thickness and degree of deformation.

This manual adjustment design offers the following unique advantages: First, it completely eliminates reliance on PLCs, servo motors, and hydraulic systems, resulting in a highly simplified electrical system and a significant reduction in potential failure points. Second, in production scenarios involving small batches and multiple product varieties, operators can manually adjust parameters at any time based on the actual conditions of different batches of sheet metal, without the need for programming, ensuring flexible switching. Third, both the initial purchase cost and long-term maintenance costs are significantly lower than those of hydraulic or CNC models of the same specifications, making it particularly suitable for small and medium-sized processing enterprises with limited budgets.

Applications

• Leveling of Laser-Cut Parts: During the laser cutting process, the heat-affected zone causes localized stress release in the sheet metal, leading to warping at the edges or bulging in the center. The 80-roll leveling machine effectively eliminates this type of thermal deformation, providing flat blanks for subsequent bending and welding.

• Medium-to-Thick Sheet Processing: Medium-thickness sheets (2–16 mm) are the ideal processing material for this machine, widely used for sheet metal pre-processing in fields such as construction machinery structural components, ship sections, wind turbine tower connection plates, and bridge components.

• Workshops with Frequent Batch Changes: The advantages of manual adjustment are particularly evident in such scenarios—there is no need to wait for programming and debugging. Operators can visually assess the sheet shape based on experience and make fine adjustments directly via the handwheel, ensuring an immediate response. The time required for switching between individual parts can be kept within one minute.

Maintenance Guidelines

• Regularly check the zero-point accuracy of the dial gauge to ensure the reliability of gap adjustment readings;

• Clean the working roll surfaces regularly to prevent metal debris from adhering and causing indentations on the sheet metal;

• Lubricate the worm gear mechanism with grease once every two weeks to prevent increased clearance due to wear, which could affect adjustment accuracy;

• Replace the lubricating oil in the gearbox one month after initial use, and thereafter every six months;

• Before prolonged shutdown, raise the movable crossbeam to its highest position to prevent permanent deformation of the work rollers caused by prolonged pressure.