I. Thorough Assembly Inspection

To guarantee impeccable performance, each leveling machine undergoes meticulous assembly inspection. Here’s what it entails:

Contact Clearance Verification:

  • The gap between the leveling roll and the support roll must not exceed 0.05mm.
  • Under no-load conditions, adjustments are made based on measured values post-assembly. Once set during installation, these clearances remain unchanged.
  • Under load conditions, support rolls must rotate at least 85% of the total, with no non-rotating rolls on the initial 4 rolls at the feed end.

Surface Precision Checks:

  • Parallelism tolerance between upper and lower leveling roll surfaces must not surpass 0.035mm/m after assembly.
  • Flatness tolerance at five different positions of the leveling roll should not exceed 0.05mm.
  • The alignment of the left and right frame windows’ bottom and center surfaces must be within a 0.05mm tolerance.

Exterior Coating Evaluation:

  • The leveling machine’s appearance should be visually appealing, boasting a smooth, lustrous surface.
  • Coating quality adheres to JB/T5000.12 standards, ensuring no issues like collisions, scratches, or peeling.

II. Thorough Empty Operation Test

Before being put into actual operation, each leveling machine undergoes a comprehensive empty operation test, covering various critical aspects:

Pre-Empty Operation Checks:

  • Injection of oil into lubrication points to ensure proper lubrication without leaks.
  • Adjustment of contact clearance between support roll and leveling roll as per assembly requirements, along with tightening of all fastening parts.
  • Inspection of pressing mechanism and swinging mechanism assembly to meet stipulated requirements.
  • Testing the flexibility of leveling roll transmission and checking for any jams in the pressing and swinging mechanisms.

Main Transmission System Test:

  • Idle operation for over 12 hours, including reverse operation for 1 hour, and a minimum of 3000 reciprocating movements to assess operational performance.
  • Bearing temperature rise should not exceed 45°C during continuous operation.
  • Adequate lubrication without any oil leakage is ensured.
  • Noise levels from gear transmission parts should not exceed 85dB.

Pressing Mechanism and Swinging Mechanism Tests:

  • Synchronization of four pressing screws during two reciprocating strokes.
  • Verification of correct up and down strokes alignment and positioning of the dial indicator needle.

Lower Support Roll Adjustment Mechanism Test:

  • Clutch engagement and disengagement performed twice at each clutch position.
  • Verification of support roll rise and fall, ensuring compliance with design requirements and correct positioning of leveling dial indicator.

Load Testing Considerations:

  • Load testing is not typically conducted in the leveling machine production workshop but can be arranged if requested by the customer.
  • During load testing, suitable steel plates are utilized, and after leveling, the steel undergoes inspection multiple times to meet national standard requirements for plate curvature or wave quality while checking for surface scratches.
Leveling Machine
Leveling Machine