 |
| Quantity: | |
|---|---|
JZ-60
Precision Levelers for Laser Cut Sheet Metal and Heavy Plates (1.0 to 6 mm thick)
In the world of modern manufacturing, especially in industries such as automotive, aerospace, metal fabrication, and construction, the demand for high-quality, flat sheet metal and heavy plate components is critical. Laser cutting, plasma cutting, and punching are common processes used to shape and cut metal sheets and plates. However, these processes can leave behind distortions such as warps, bows, or residual stresses in the material. This is where precision levelers come into play. Precision levelers are designed to eliminate these distortions, ensuring that the material is perfectly flat and ready for further processing or assembly.
This article will introduce precision levelers for laser cut sheet metal and heavy plates ranging in thickness from 1.0 mm to 6.0 mm, with passage widths available from 400 mm to 2200 mm. These machines are capable of leveling a variety of materials, including laser cut, plasma cut, and punched parts, as well as larger sheets and plates.
A precision leveler is a machine used to straighten and flatten metal sheets or plates that have been deformed due to manufacturing processes such as laser cutting, plasma cutting, or punching. These processes can introduce stresses or deformations into the metal, causing it to become warped, bowed, or twisted. A precision leveler uses a series of rollers arranged in a specific pattern to apply controlled pressure to the metal, gradually bending it in the opposite direction to eliminate these deformations.
The precision leveler is equipped with advanced adjustable roller gaps and pressure control systems, allowing it to work with a range of material thicknesses and ensure high levels of accuracy in the final product. The result is a perfectly flat sheet or plate with minimal residual stress, which is essential for applications requiring precise fitting, welding, or coating.
1. Material Thickness Range: 1.0 mm to 6.0 mm
Precision levelers designed for laser cut and plasma cut parts typically handle a variety of sheet thicknesses, from thin sheets of 1.0 mm to medium-thick plates of 6.0 mm. The thickness range allows the machine to process both thin sheets that require finer adjustments and thicker plates that demand higher levels of force to achieve flatness.
For instance, laser-cut parts, especially when thinner than 3.0 mm, may suffer from slight thermal distortions, which are easily corrected with a precision leveler. On the other hand, plasma-cut parts and thicker plates (up to 6 mm) may require more robust equipment capable of applying higher bending forces to straighten them.
2. Passage Widths Available: 400 mm to 2200 mm
Precision levelers for laser cut and plasma cut parts come with a wide range of passage widths to accommodate various material sizes. These widths range from 400 mm to 2200 mm, ensuring that the machine can handle everything from small, intricate components to large industrial sheets.
The adjustable passage width allows manufacturers to process a broad variety of sheet sizes and part types. A narrower passage width (e.g., 400 mm or 600 mm) is suitable for small or specialized parts, while a wider passage width (e.g., 1800 mm, 2000 mm, or 2200 mm) allows the machine to handle larger, heavy plates often used in construction or heavy machinery manufacturing.
3. Versatility for Multiple Materials
One of the primary benefits of a precision leveler is its ability to handle a wide range of materials, including:
Laser Cut Parts: Laser cutting can create clean edges but may introduce heat-induced deformations in the material. A precision leveler can correct these distortions, ensuring the sheet remains flat and smooth.
Plasma Cut Parts: Plasma cutting typically leaves rougher edges and may cause warping due to the heat generated during the process. The leveler can straighten the sheet, making it more suitable for further processes like welding or coating.
Punched Parts: Punched parts, especially when produced from thicker metal sheets, may suffer from edge distortions or internal stresses. A precision leveler can remove these distortions and prepare the part for assembly.
Sheets and Plates: The precision leveler is ideal for handling not just individual parts but also large sheets and plates, making it suitable for various applications in metalworking and heavy fabrication industries.
4. Adjustable Roller Gap and Pressure Control
Precision levelers use a series of rollers, which are set at adjustable gaps to accommodate different material thicknesses. The machine’s roller gap adjustment allows it to work effectively across the entire range of materials from 1.0 mm to 6.0 mm. For thinner sheets, the gap is set narrower to apply light pressure, while for thicker plates, the gap is widened, allowing the rollers to apply higher bending forces to straighten the material.
In addition to adjusting the roller gap, the machine also features pressure control to ensure that the correct amount of force is applied at each stage of the leveling process. This prevents over-straightening, which could lead to deformation or damage, while also ensuring that the material is flattened uniformly across its entire width.
5. Speed and Efficiency
Precision levelers are typically capable of processing materials at speeds ranging from 0 to 12 meters per minute, depending on the material thickness and the level of flatness required. This speed range allows manufacturers to optimize the machine’s throughput based on their specific needs, whether they are producing small batches of specialized parts or running high-volume production lines. Faster speeds are generally used for thinner sheets, while thicker materials require slower speeds to ensure that the leveling process is applied effectively.
6. Advanced Control Systems
Modern precision levelers come equipped with CNC (Computer Numerical Control) or PLC (Programmable Logic Controller) systems, which allow for precise control over the leveling process. These systems monitor various parameters, including roller gap, pressure, and material thickness, and make adjustments in real-time to ensure that the leveling process is carried out accurately.
The control system often includes digital displays and feedback mechanisms that allow operators to make fine adjustments based on the material being processed. Some systems may even feature automatic adjustment capabilities, allowing the machine to self-optimize for different material properties without requiring manual input.
7. Robust Build Quality
Precision levelers are built to last, with heavy-duty frames and high-strength components that can withstand the stresses involved in leveling metal sheets and plates. The robust construction ensures the machine remains stable during operation, providing accurate and consistent results over long production runs.
The process of leveling with a precision leveler involves several key stages:
Material Entry
The metal sheet or plate is loaded into the precision leveler, either manually or automatically, depending on the machine’s configuration. The material is fed into the machine through a set of guide rollers that ensure proper alignment.
Roller Interaction
Once the material is aligned, it passes through a series of upper and lower rollers. These rollers apply a combination of bending forces to the sheet, gradually flattening it as it moves through the machine. The rollers work together in an alternating pattern to ensure that the material is bent in the opposite direction of its distortions, effectively removing warps and twists.
Pressure and Gap Adjustment
The machine’s control system continuously adjusts the roller gap and pressure to match the thickness of the material and the level of distortion. This dynamic adjustment ensures that the correct amount of force is applied to achieve a perfectly flat sheet without over-straining the material.
Exit and Quality Check
Once the sheet has passed through the rollers, it exits the machine and is inspected for quality. Some machines include automatic flatness measurement systems to ensure that the material meets the required specifications. If necessary, further adjustments are made to achieve the desired result.
Precision levelers are used in various industries where flatness is crucial, including:
Automotive Manufacturing: To produce body panels, chassis components, and other structural elements with high precision.
Aerospace: For leveling critical parts that require exact flatness for safety and performance.
Heavy Equipment and Construction: To prepare large sheets and plates used in machinery, structural beams, and support elements.
Metal Fabrication: For leveling laser cut, plasma cut, and punched parts used in different fabrication processes.
Appliance Manufacturing: For processing sheet metal used in the production of household appliances, ensuring flatness for assembly and coating.
Precision Levelers for Laser Cut Sheet Metal and Heavy Plates (1.0 to 6 mm thick)
In the world of modern manufacturing, especially in industries such as automotive, aerospace, metal fabrication, and construction, the demand for high-quality, flat sheet metal and heavy plate components is critical. Laser cutting, plasma cutting, and punching are common processes used to shape and cut metal sheets and plates. However, these processes can leave behind distortions such as warps, bows, or residual stresses in the material. This is where precision levelers come into play. Precision levelers are designed to eliminate these distortions, ensuring that the material is perfectly flat and ready for further processing or assembly.
This article will introduce precision levelers for laser cut sheet metal and heavy plates ranging in thickness from 1.0 mm to 6.0 mm, with passage widths available from 400 mm to 2200 mm. These machines are capable of leveling a variety of materials, including laser cut, plasma cut, and punched parts, as well as larger sheets and plates.
A precision leveler is a machine used to straighten and flatten metal sheets or plates that have been deformed due to manufacturing processes such as laser cutting, plasma cutting, or punching. These processes can introduce stresses or deformations into the metal, causing it to become warped, bowed, or twisted. A precision leveler uses a series of rollers arranged in a specific pattern to apply controlled pressure to the metal, gradually bending it in the opposite direction to eliminate these deformations.
The precision leveler is equipped with advanced adjustable roller gaps and pressure control systems, allowing it to work with a range of material thicknesses and ensure high levels of accuracy in the final product. The result is a perfectly flat sheet or plate with minimal residual stress, which is essential for applications requiring precise fitting, welding, or coating.
1. Material Thickness Range: 1.0 mm to 6.0 mm
Precision levelers designed for laser cut and plasma cut parts typically handle a variety of sheet thicknesses, from thin sheets of 1.0 mm to medium-thick plates of 6.0 mm. The thickness range allows the machine to process both thin sheets that require finer adjustments and thicker plates that demand higher levels of force to achieve flatness.
For instance, laser-cut parts, especially when thinner than 3.0 mm, may suffer from slight thermal distortions, which are easily corrected with a precision leveler. On the other hand, plasma-cut parts and thicker plates (up to 6 mm) may require more robust equipment capable of applying higher bending forces to straighten them.
2. Passage Widths Available: 400 mm to 2200 mm
Precision levelers for laser cut and plasma cut parts come with a wide range of passage widths to accommodate various material sizes. These widths range from 400 mm to 2200 mm, ensuring that the machine can handle everything from small, intricate components to large industrial sheets.
The adjustable passage width allows manufacturers to process a broad variety of sheet sizes and part types. A narrower passage width (e.g., 400 mm or 600 mm) is suitable for small or specialized parts, while a wider passage width (e.g., 1800 mm, 2000 mm, or 2200 mm) allows the machine to handle larger, heavy plates often used in construction or heavy machinery manufacturing.
3. Versatility for Multiple Materials
One of the primary benefits of a precision leveler is its ability to handle a wide range of materials, including:
Laser Cut Parts: Laser cutting can create clean edges but may introduce heat-induced deformations in the material. A precision leveler can correct these distortions, ensuring the sheet remains flat and smooth.
Plasma Cut Parts: Plasma cutting typically leaves rougher edges and may cause warping due to the heat generated during the process. The leveler can straighten the sheet, making it more suitable for further processes like welding or coating.
Punched Parts: Punched parts, especially when produced from thicker metal sheets, may suffer from edge distortions or internal stresses. A precision leveler can remove these distortions and prepare the part for assembly.
Sheets and Plates: The precision leveler is ideal for handling not just individual parts but also large sheets and plates, making it suitable for various applications in metalworking and heavy fabrication industries.
4. Adjustable Roller Gap and Pressure Control
Precision levelers use a series of rollers, which are set at adjustable gaps to accommodate different material thicknesses. The machine’s roller gap adjustment allows it to work effectively across the entire range of materials from 1.0 mm to 6.0 mm. For thinner sheets, the gap is set narrower to apply light pressure, while for thicker plates, the gap is widened, allowing the rollers to apply higher bending forces to straighten the material.
In addition to adjusting the roller gap, the machine also features pressure control to ensure that the correct amount of force is applied at each stage of the leveling process. This prevents over-straightening, which could lead to deformation or damage, while also ensuring that the material is flattened uniformly across its entire width.
5. Speed and Efficiency
Precision levelers are typically capable of processing materials at speeds ranging from 0 to 12 meters per minute, depending on the material thickness and the level of flatness required. This speed range allows manufacturers to optimize the machine’s throughput based on their specific needs, whether they are producing small batches of specialized parts or running high-volume production lines. Faster speeds are generally used for thinner sheets, while thicker materials require slower speeds to ensure that the leveling process is applied effectively.
6. Advanced Control Systems
Modern precision levelers come equipped with CNC (Computer Numerical Control) or PLC (Programmable Logic Controller) systems, which allow for precise control over the leveling process. These systems monitor various parameters, including roller gap, pressure, and material thickness, and make adjustments in real-time to ensure that the leveling process is carried out accurately.
The control system often includes digital displays and feedback mechanisms that allow operators to make fine adjustments based on the material being processed. Some systems may even feature automatic adjustment capabilities, allowing the machine to self-optimize for different material properties without requiring manual input.
7. Robust Build Quality
Precision levelers are built to last, with heavy-duty frames and high-strength components that can withstand the stresses involved in leveling metal sheets and plates. The robust construction ensures the machine remains stable during operation, providing accurate and consistent results over long production runs.
The process of leveling with a precision leveler involves several key stages:
Material Entry
The metal sheet or plate is loaded into the precision leveler, either manually or automatically, depending on the machine’s configuration. The material is fed into the machine through a set of guide rollers that ensure proper alignment.
Roller Interaction
Once the material is aligned, it passes through a series of upper and lower rollers. These rollers apply a combination of bending forces to the sheet, gradually flattening it as it moves through the machine. The rollers work together in an alternating pattern to ensure that the material is bent in the opposite direction of its distortions, effectively removing warps and twists.
Pressure and Gap Adjustment
The machine’s control system continuously adjusts the roller gap and pressure to match the thickness of the material and the level of distortion. This dynamic adjustment ensures that the correct amount of force is applied to achieve a perfectly flat sheet without over-straining the material.
Exit and Quality Check
Once the sheet has passed through the rollers, it exits the machine and is inspected for quality. Some machines include automatic flatness measurement systems to ensure that the material meets the required specifications. If necessary, further adjustments are made to achieve the desired result.
Precision levelers are used in various industries where flatness is crucial, including:
Automotive Manufacturing: To produce body panels, chassis components, and other structural elements with high precision.
Aerospace: For leveling critical parts that require exact flatness for safety and performance.
Heavy Equipment and Construction: To prepare large sheets and plates used in machinery, structural beams, and support elements.
Metal Fabrication: For leveling laser cut, plasma cut, and punched parts used in different fabrication processes.
Appliance Manufacturing: For processing sheet metal used in the production of household appliances, ensuring flatness for assembly and coating.
