Roll System for High Precision 23 Roll Levelers
On a 23 roll leveler the roll system is the machine. Its operating parameters decide the geometric accuracy of the finished product, the stability of the process and the output of the whole continuous line, which is why the calibration of the multi roll configuration matters more than any single component.
- For high precision 23 roll levelers
- Handles copper, aluminum and specialty steel coil
- Micro stress elimination technology
- Production yield improvement reported up to 25 percent
Key Benefits
What the roll system delivers.
Flatness For Critical Surfaces
Precisely calibrated multi roll configuration delivers the flatness required for critical applications such as etching, where surface integrity cannot be compromised.
Defects Eliminated At Source
Ripple patterns, edge waves and stress induced deformations are removed rather than hidden.
Yield Improvement
Consistent quality output has been reported to enhance production yield by up to 25 percent on this configuration.
Where It Is Used
Materials and applications.
- Copper strip leveling for electronics
- Aluminum coil processing
- Specialty steel coil leveling
- Feed preparation for etching applications
Who It Is For
- Copper and aluminum strip processors
- Producers supplying etching grade material
- Plants with high rejection rates on flatness
- Machine owners rebuilding a 23 roll leveler
Problems It Solves
- Ripple patterns on thin non ferrous strip
- Edge waves on wide coil
- Stress induced deformation appearing after cutting
- Yield loss on high value material
Technical Features
System construction.
Calibrated Multi Roll Configuration
The 23 roll arrangement is calibrated as a system so leveling force is distributed precisely across the strip.
Micro Stress Elimination
The technology targets residual micro stress rather than only visible shape defects.
Integrated Precision Control
A precision control system holds settings so quality output is consistent across coils.
Specifications
System configuration depends on material and gauge. Reference data is below.
| Configuration | 23 roll high precision leveler roll system |
|---|---|
| Materials | Copper, aluminum and specialty steel coil |
| Defects Addressed | Ripple patterns, edge waves, stress induced deformation |
| Reported Yield Gain | Up to 25 percent |
| Hardness Consistency | Within 2 HRC across the roll set |
| Plating Reference | Around 0.05 mm where applied |
| Material Strength Reference | Up to 800 MPa class strip |
Materials
- Alloy steel roll bodies
- Hardened and ground working surfaces
- Optional chrome plated contact surfaces
Manufacturing Process
Material And Gauge Study
Strip material, thickness, width and flatness target set the roll configuration.
Roll Production
Work, intermediate and support rolls are produced as a matched system.
Hardness Control
Hardness is held within 2 HRC across the set so leveling force is even.
Assembly And Calibration
The system is assembled and calibrated before shipment.
Quality Control
- Hardness consistency verification within 2 HRC
- Roll geometry and runout inspection
- Surface finish measurement
- System calibration record
Customization Options
- Roll count and diameter for your leveler
- Material specification for copper, aluminum or specialty steel
- Surface treatment per material
- Complete replacement system or individual rolls
Use Guide
- Calibrate the system after installation before running production material
- Keep hardness records with the machine file
- Match leveling settings to material and gauge, not to a single recipe
- Replace rolls as a system to preserve the calibration
How It Compares
Against fewer roll arrangements.
| Levelers with fewer rolls | A 23 roll configuration gives finer control over micro stress for thin high value strip. |
|---|---|
| Replacing individual rolls | System supply keeps hardness within 2 HRC across the set so leveling force stays even. |
| Offline flattening | In line leveling with micro stress elimination keeps material flat after cutting and etching. |
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Read MoreRoll System for High Precision 23 Roll Leveler FAQ
Which materials is this system for?
Copper, aluminum and specialty steel coils, including material used in critical etching applications.
What defects does it remove?
Ripple patterns, edge waves and stress induced deformations, through a calibrated multi roll configuration with micro stress elimination.
What yield improvement is realistic?
Up to 25 percent has been reported for this configuration. The actual gain depends on your current rejection rate and material.
How consistent is hardness across the set?
Hardness is held within 2 HRC across the roll set so leveling force is distributed evenly.
Can you supply a system for an existing 23 roll leveler?
Yes. Send the machine drawing or the roll dimensions and we produce a matched replacement system.
What is needed to quote?
Material, thickness and width range, flatness target, machine drawing and quantity.
Rebuild Your 23 Roll Leveler
Send your material programme and machine data and we quote a complete roll system.