Scale breaker for Aluminum sheet production line from china top 10 profession manufacturer
1. General Description
The 1850 scale breaker is a specialized finishing equipment designed for the surface treatment of aluminum strip and sheet. It is widely used in production lines for aluminum and aluminum alloy coils. The equipment is primarily employed to remove the dense oxide scale (skin) adhering to the surface of aluminum strip, while simultaneously performing stretch‑bend leveling to eliminate shape defects such as edge wave, center buckle, and crossbow. This prepares the strip for subsequent processes including cleaning, coating, and further fabrication, ensuring a high‑quality surface.
The designation “1850” refers to the maximum working width of 1850 mm, placing this machine among the core equipment for wide‑format aluminum strip processing. This model was independently developed by a renowned domestic non‑ferrous metal processing design institute, building upon advanced international technologies. Its successful development filled a domestic gap in the field of wide‑width, high‑speed tension leveling and scale breaking for aluminum strips.
2. Working Principle
The 1850 scale breaker operates on the tension‑bend leveling and scale‑breaking principle, mechanically removing the oxide layer from the aluminum strip surface.
The process proceeds as follows:
Tensioning: The aluminum strip is subjected to longitudinal tension between the tension rollers of the unit, causing tensile plastic deformation.
Bending: The strip passes sequentially through multiple sets of bending rollers. Under repeated large‑angle bending, shear stresses develop between the aluminum substrate and the surface oxide layer.
Oxide cracking: Because the aluminum substrate and the oxide layer have different plastic deformation capacities, the dense surface oxide layer undergoes uniform micro‑cracking and partial spalling under the combined action of tension and bending.
Leveling and shaping: The strip then passes through the leveling roller system, which removes residual stresses and various shape defects.
After this process, the fractured scale is more readily removed in subsequent cleaning stages, and the pickling solution can directly contact the base aluminum surface, significantly improving removal efficiency.
3. Equipment Composition and Structure
The 1850 scale breaker typically adopts a “three‑bend, one‑level” or similar roller configuration. Its main structural components include:
3.1 Frame System
A box‑type integral frame with high rigidity and strength, capable of withstanding stable operation under high tension.
3.2 Bending Roller Units
Usually equipped with three bending units, each consisting of upper and lower bending roller assemblies. Each unit has independent reduction adjustment mechanisms, allowing flexible control of bending angle and reduction according to different incoming material specifications and process requirements.
3.3 Leveling Roller Unit
One leveling unit, comprising leveling rollers and anti‑crossbow roller sets, used to eliminate shape defects generated after bending.
3.4 Roll Gap Fine‑Adjustment Device
Each fine‑adjustment set includes a gear motor, two worm‑gear screw jacks, and supporting brackets, enabling precise control of the vertical position of each roller group to ensure accurate process parameter execution.
3.5 Auxiliary Systems
Quick‑opening device: The upper bending roller group is equipped with a quick‑opening mechanism to facilitate threading and emergency stopping.
Blow‑off / dust removal system: Includes upper and lower blow‑off nozzle assemblies to promptly remove dislodged scale debris.
Dust discharge chute: Designed at the bottom of the frame, connected to the dust extraction system to keep the scale‑breaking process clean.
4. Main Technical Parameters
| Parameter | Specification |
|---|---|
| Model | 1850 Scale Breaker (Tension‑Leveling Unit) |
| Applicable materials | Pure aluminum and aluminum alloys (1000, 3000, 5000, 8000 series, etc.) |
| Incoming thickness | 0.1 – 2.5 mm |
| Incoming width | 700 – 1700 mm |
| Maximum working width | 1850 mm |
| Line speed | Up to 300 m/min |
| Tension accuracy | ±0.5% |
| Elongation accuracy | ±0.01% |
| Cleaning speed | Max. 250 m/min |
Note: Specific parameters may vary depending on manufacturer design and customer requirements.
5. Performance Features
5.1 High Scale‑Breaking Efficiency
Through repeated bending by multiple bending roller groups, the oxide layer on the aluminum surface is uniformly cracked. The integrated blow‑off and dust removal system promptly removes dislodged particles, preventing secondary contamination.
5.2 Excellent Shape Leveling Capability
Effectively eliminates various three‑dimensional shape defects, including double‑edge wave, single‑edge wave, center buckle, two‑rib wave,warping, and crossbow.
5.3 High Precision Control
Equipped with precision roll‑gap fine‑adjustment devices and tension control systems, ensuring consistent product quality and processing accuracy.
5.4 High Degree of Automation
Supports fully automatic coil loading, cleaning, leveling, unloading, and edge trimming, greatly improving operational efficiency.
5.5 Broad Width Adaptability
The 1850 mm working width satisfies the processing requirements of most wide‑format aluminum strip products, making it widely applicable in new energy vehicle battery casings, PS plate substrates, decorative materials, and more.
6. Application Fields
The 1850 scale breaker is mainly used in the following areas:
Aluminum and aluminum alloy strip production lines – as a key finishing‑section equipment.
New energy vehicle battery casings and component materials – for aluminum strips with thicknesses of 0.3–2.5 mm.
PS plate substrates – surface treatment for printing aluminum plates.
Decorative materials – aluminum strips for architectural decoration.
Aluminum foil stock – intermediate processing for battery foil and packaging foil.
This equipment has already been successfully commissioned at major domestic aluminum processors including CHALCO and Zhongfu High‑Precision Aluminum.
7. Conclusion
The 1850 scale breaker is a core finishing machine for aluminum strip processing, integrating scale removal (oxide layer breaking) and tension‑bend leveling into one unit. It features wide processing width, high speed, excellent leveling accuracy, and a high degree of automation. The successful domestic development of this equipment has filled a technological gap in China’s wide‑width, high‑efficiency aluminum strip leveling and scale‑breaking capabilities, providing strong equipment support for the high‑quality development of the domestic aluminum processing industry.
