Roller Cassettes for 1550mm Tension leveler
The roll cassettes is an important component of the tension balancing machine structure, whose main function is to support the working roll and intermediate roll to minimize bending and deformation, which directly affects the characteristics and quality of the produced sheet/coil. The roll box (rolling mill frame) is the core of any rolling mill. We can design and manufacture high-precision and durable roll boxes to ensure your production runs continuously and achieves excellent product quality.
Main advantages of roll cassettes：
- High Precision Rolling Performance: Through precision CNC machining and robotic assembly processes, we guarantee consistent geometric parameters with dimensional tolerances within ±0.05mm. The optimized roller alignment system maintains stable product geometry throughout continuous operation, ensuring uniform thickness distribution and superior surface quality across all finished materials.
- Enhanced Reliability Engineering: Constructed with high-strength alloy steel (DIN 1.2344 equivalent) and premium load-bearing units rated for dynamic loads up to 8 tons, our roller boxes deliver exceptional durability. The engineered solution withstands continuous high-intensity operation with proven service life exceeding 20,000 hours under maximum load conditions, significantly outperforming industry standards.
- Comprehensive Versatility and Adaptability: Our technical solutions cover the entire spectrum of rolling applications – from standard profiles and plates to complex special sections including U-channels, I-beams, and custom geometric shapes. The adaptable design accommodates material thicknesses from 0.5mm to 12mm with quick-adjustment features for rapid production changeovers.
- Rapid Replacement and Maintenance Optimization: The modular architecture incorporates standardized interfaces and quick-disconnect mechanisms that reduce maintenance downtime by up to 60%. Complete roller shaft replacement can be accomplished within 30 minutes, compared to 2-3 hours required for conventional designs, dramatically improving equipment availability.
- Production Efficiency Optimization: Our roller box systems contribute to scrap rate reduction of 15-20% through precise material guidance and tension control. The optimized design increases overall mill capacity by 25-30% through enhanced processing speed and reduced operational interruptions, delivering substantial ROI through improved production economics.
These features ensure efficient operation of high-speed, large, and high-precision lathe spindles.
Technical specifications for roll cassettes components:
- Enhanced Structural Rigidity: The heavy-duty box-type construction utilizing high-strength steel (minimum yield strength 355 MPa) minimizes elastic deformation under rolling pressures up to 3000 kN. Finite element analysis-optimized design ensures deformation remains below 0.1mm under maximum load conditions, maintaining perfect roll alignment and consistent product quality throughout continuous operation, compliant with ISO 9010 structural standards.
- Precision Rolling Mill System: Incorporates precisely ground work rolls with diameter tolerance of ±0.01mm and double-row cylindrical roller bearings with dynamic load capacity of 450 kN. The system maintains product dimensional accuracy within ±0.05mm, supported by real-time thickness monitoring and automatic feedback adjustment, achieving consistent quality that meets ASTM A568 dimensional standards.
- Advanced Cooling Efficiency: The integrated multi-channel cooling system employs precisely directed nozzle arrays and temperature-controlled circulation, maintaining optimal operating temperature between 35-45°C. This precise thermal management extends equipment service life by 30-40% compared to conventional systems while preventing thermal deformation and preserving material properties during continuous high-speed operation.
- Rapid Shaft Replacement System: Modular shaft coupling design with standardized interfaces and quick-disconnect mechanisms reduces replacement time by 70%. The engineered solution enables complete shaft changeover within 15 minutes using standard tools, compared to 45-60 minutes required for traditional designs, significantly improving equipment utilization rates and production flexibility.
- Automated Precision Adjustment: Features servo-electric adjustment system with positional accuracy of ±0.05mm for precise roll gap control. The programmable logic controller (PLC) with human-machine interface (HMI) allows real-time process parameter adjustments within seconds, facilitating optimal rolling conditions for different materials and specifications while maintaining consistent product quality.
Application:
Roll cassettes are indispensable in industries that require high-precision metal pressure processing:
- Automotive industry: used for producing automotive body panels and structural components to ensure uniformity and strength.
- Household appliances: It is crucial to manufacture sturdy metal casings, such as refrigerators and washing machines.
- Building structure: It can produce steel plates and sections with constant flatness, which is crucial for the integrity of the building structure.
- High end manufacturing: supports high-speed processing of special alloys for aerospace and electronics industries.
