What does a rollers leveling machine do?
2025-10-14 17:00
A rollers leveling machine is a crucial piece of equipment used to improve the surface flatness of metal materials. Through advanced technology and design, precision roller levelers address common problems such as warping, residual stress, and surface unevenness during metalworking. KINGREAL CEILING MACHINERY engineers utilize the "Bausinger effect." By repeatedly twisting the sheet metal, the rollers leveling machine gradually aligns the metal fibers, eliminating internal stresses and restoring and improving flatness. Precision roller levelers’ accuracy can reach micron levels. This article will explore in detail the rollers leveling machine's operating principle, structural features, applications, and importance in metalworking.
How a Precision Roller Levelers Work?
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The core function of a rollers leveling machine is to improve the flatness of metal materials through multiple passes. Specifically, the precision roller levelers utilizes staggered support rollers to ensure even force distribution under heavy loads, preventing bending and deformation. This design provides the rollers leveling machine with sufficient rigidity to ensure stable, efficient, and high-quality leveling performance. The precision roller levelers' operating process generally involves the following steps: Material Feeding: The metal sheet to be leveled is fed into the rollers leveling machine via a feed system. Leveling Process: The metal sheet undergoes twisting and compression within the precision roller levelers, gradually aligning the metal fibers and eliminating internal stress. Leveling Output: The leveled metal sheet is discharged with significantly improved surface flatness and dimensional accuracy. This leveling process significantly improves the stability and consistency of the metal material during subsequent processing. |  |
Structural Features of Rollers Leveling Machine
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The design and structure of the precision roller levelers determine its performance and application effectiveness. The following are the main structural components and features of the rollers leveling machine:
1. Support rollers for precision roller levelers
The support rollers are a key component of the rollers leveling machine and are typically designed with extra width to increase load and auxiliary pressure, extending their service life. Stringent hardness and concentricity requirements are imposed on the support rollers. They are typically made of GCr15 steel, forged and machined to ensure high strength and wear resistance.
2. Straightening rollers for precision roller levelers
Straightening rollers are typically made of high-hardness GCr15 steel, heat-treated to a hardness of HRC 60-64, ensuring they resist deformation under high forces. The precision positioning assembly of the straightening rollers can withstand high workloads and ensure effective leveling.
3. Gearbox for rollers leveling machine
The precision roller levelers' gearbox is made of 20CrMnTi steel, forged, tempered, and carburized, providing efficient and precise transmission capabilities. The coupling is designed as a universal joint, ensuring stable transmission, minimizing backlash, and improving the overall performance of the leveler.
4. Upper and lower machine frames for rollers leveling machine
The precision roller levelers' frame is typically constructed of box-shaped, cross-welded steel (Q355 low-carbon steel) with an anti-twist design to ensure structural stability. The seamless weld manufacturing process eliminates defects such as slag inclusions and porosity, extending the rollers leveling machine's service life.
5. Power transmission for precision roller levelers
The rollers leveling machine's power transmission system connects the upper and lower rollers via universal joints, offering high load capacity, long life, and stable operation. This design effectively prevents vibration during operation and improves the precision roller levelers' overall performance.
6. Electrical control for rollers leveling machine
The precision roller levelers' electrical control system centrally controls the main circuit motor and is equipped with a thermal circuit breaker to ensure safe operation. Moving parts are equipped with limit switches and emergency stop devices to ensure operator safety.
7. Touch screen HML for rollers leveling machine
The precision roller levelers are equipped with a touch screen HML, which supports visual input, editing, modification, and storage of process parameters. Users can preset 25 process parameters, significantly improving the rollers leveling machine's operating accuracy and production efficiency.
8. Safety light barrier for precision roller levelers
The safety light barrier detects objects within the work area during operation and immediately stops the rollers leveling machine if an obstacle is detected. This feature effectively protects the operator and prevents accidents.
Different Precision Roller Levelers Solutions
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KINGREAL CEILING MACHINERY offers a variety of rollers leveling machine solutions to meet customer needs for processing different materials and thicknesses. The following are two featured precision roller levelers solutions:
Four-high rollers leveling machine solution Structure: Work Roller + Backup Roller Advantages: Durable, easy to maintain, efficient, and cost-effective Application: Suitable for carbon steel materials with low surface quality requirements. |  |
Six-high precision roller levelers Solution Structure: Work Roll + Intermediate Roll + Backup Roll Advantages: Excellent flatness, zero surface marks, and minimal residual stress Applications: Suitable for precision machining of materials such as stainless steel, aluminum, and advanced high-strength steel (AHSS). The intermediate roll of the six-high precision roller levelers is crucial, isolating stress and ensuring even pressure distribution, resulting in ultimate flatness and perfect surface protection. |  |
Applications of Rollers Leveling Machine
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Precision roller levelers are widely used in various industries, particularly in automotive, aviation, metalworking, and shipbuilding. Specific applications include:
Automotive: Rollers leveling machine improve the flatness of metal materials in the production of automotive parts, ensuring component safety and consistency.
Aerospace: The aviation industry places extremely high demands on material flatness, and precision roller levelers meet these stringent standards to ensure aircraft safety.
Metalworking: In the metalworking industry, rollers leveling machine eliminate internal stress generated during cutting and welding, improving material quality and service life.
Shipbuilding: During the shipbuilding process, precision roller levelers help improve the surface quality of the hull material, ensuring its stability and safety when sailing in the water.
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