19 Roll Leveler with High-Precision
In today’s pursuit of maximum production efficiency and product quality, the stability and maintainability of the leveling process have become a critical bottleneck in finishing lines. Our newly developed 19-roll leveler is designed specifically to break this bottleneck. It is more than just a leveler; it’s a comprehensive productivity solution built around the core principles of Rapid Maintenance and Precise Control.
Core Design Philosophy of 19 Roll Leveler: Maximize Uptime, Minimize Downtime
We understand that unplanned downtime is a primary cost driver. Therefore, “ease of maintenance” was a top priority from the initial design stage.
Quick-Open Housing & Integral Cassette: The top housing can be opened quickly via hydraulics, providing ample space for threading and troubleshooting. The standard 23-roll integral cassette (9 top / 10 bottom work rolls + backup rolls) can be safely and smoothly pulled out or pushed into the machine as a complete unit by a single operator using a simple track and hand-crank mechanism, slashing traditional roll change or maintenance time from hours to minutes.
Multi-Function Dedicated Lifting Tool: The accompanying lifting tool allows for the integrated handling of the entire cassette and features a top cassette tilting function, drastically simplifying offline inspection, grinding, and maintenance of the roll assembly.
Precision Control of 19 Roll Leveler: From “Experience-Based” to “Data-Driven”
We have moved beyond traditional, experience-dependent adjustment methods by implementing a fully digital closed-loop control system.
True Roll Gap Measurement: Magnetostrictive displacement sensors are installed directly on both the operator and drive sides of the housing, providing real-time measurement and display of the actual roll gap. This direct measurement ensures reliable, high-fidelity data.
Accurate Opening Control: A tilting motor with an absolute encoder on the drive side allows for precise setting and locking of the top cassette’s tilt angle, enabling accurate shape correction.
Servo-Driven Lift System: The bottom work rolls are lifted by servo cylinders in direct drive configuration, with displacement measured by magnetostrictive sensors. This design eliminates all mechanical transmission components (like lead screws or gears), completely removing errors from backlash and elastic deformation, resulting in a leap forward in both lifting accuracy and response speed.
Robust Foundation of 19 Roll Leveler: The Base of All Precision
All these precision functions are built upon a solid foundation. The machine features a heavy-duty, welded monoblock housing optimized through FEA analysis. It provides extremely high rigidity and impact resistance, ensuring long-term stability of the entire machine’s accuracy, even under continuous full-load operation.
Application & Value
This machine is designed for metal strips with stringent flatness and surface quality requirements, particularly for finishing medium-to-heavy gauge stainless steel, carbon steel, and non-ferrous metals (copper, aluminum alloys). Its value lies not only in its excellent leveling performance but also in delivering quantifiable benefits: improved Overall Equipment Effectiveness (OEE) and optimized production costs by reducing downtime, lowering maintenance complexity, and enhancing process control.
We offer complete solutions from standalone machines to full finishing lines. To discuss how this equipment can meet your specific process requirements or to request detailed technical specifications, please contact our engineering team.