Tension Leveler For A 1550 mm Galvanizing Line
A tension leveler configuration for carbon steel strip on a 1550 mm galvanizing line, with the chrome plated roll set to keep it consistent.
Client Background
A carbon steel producer operating a 1550 mm continuous galvanizing line supplying sheet for automotive and construction components. The customer name is confidential.
Project Challenge
Three dimensional shape defects were surviving into the coated product, and the existing roll set was being changed more often than the maintenance plan allowed.
Customer Pain Points
- Bilateral, unilateral and middle wave in coated strip
- Warping and buckling appearing after cutting
- Roll changes interrupting continuous production
- No documented hardness on the incumbent replacement rolls
Our Solution
A tension leveler configured with two tension rolls at inlet and outlet, a roll group to amplify tension and a straightening unit carrying two rows of bending components with balancing rollers, working the strip in two stages. Chrome plated work rolls with a 5 mm hardened layer were supplied with the machine so the line had a documented roll specification from the start.
Scope Supplied
- Tension leveler configured for 1550 mm line width
- Two bending rows with balancing rollers
- Chrome plated work roll set with documented hardness
- Roll cassette with surface quenched HRC 63-65 rolls
- Installation guidance and personnel training
Manufacturing And Supply Chain
The machine and its consumable roll set were produced in the same shop, which meant the first replacement rolls were made to the identical drawing rather than reverse engineered later.
Line Study
Coil programme, line speed and incoming flatness reviewed to fix the roll configuration.
Frame Production
Frames welded, stress relieved and machined so roll centres hold under bending load.
Roll Manufacture
Work, bending and balancing rolls produced and ground as one matched set.
Assembly And Test
Roll parallelism, tension control and drive alignment verified before shipment.
Quality Control
Frame machining inspection after stress relief, roll hardness and geometry records, hydraulic and tension system testing and an assembly alignment report issued with the machine.
Final Result
The line runs a documented leveling recipe per product with a roll set whose hardness and plating specification are on file, so replacement rolls are ordered against a known drawing.
Customer Benefit
- Shape defects addressed before the coating section
- Roll replacement planned against tonnage rather than failure
- Repeat roll sets identical to the original
- Settings recorded per product at commissioning
Project Photos
Products Used In This Project
Tension Leveler for 1550 mm Galvanizing Lines
1550 mm galvanizing line tension leveler with two bending rows and balancing rollers.
View DetailsChrome Plated Working Roll for 1450 mm Tension Leveler
Consumable work roll for 1450 mm galvanizing line tension levelers, chrome plated 0.05 mm.
View DetailsTension Leveler Roll Cassettes With 16 mm Work Rolls
High accuracy cassettes with 16 mm work rolls in GCr15 or 9Cr2Mo for precision straightening.
View DetailsPremium Back Up Rolls for Leveling Machines
Deep heat treated and precision ground back up rolls, roundness held to 0.005 mm class.
View DetailsConfigure A Leveler For Your Line
Send your galvanizing line data and we come back with a configuration and a roll spares plan.