At Machine Concepts, we have extensive expertise in designing and manufacturing high-performance tension levelers. Our advanced tension levelers are engineered to precisely control and elongate metal strips, ensuring optimal flatness for demanding applications.
Operators simply input material parameters and the desired elongation, and our intelligent control system automatically configures the leveler to achieve the target elongation. The system continuously measures elongation and dynamically adjusts to maintain accuracy, delivering consistent, laser-flat material.
Tension leveling effectively removes shape defects such as edge wave, center buckle, quarter buckle and dents. Our tension levelers are available as standalone coil-to-coil lines or seamlessly integrated into galvanizing, coil coating, slitting and edge-trim lines.
- Various roll configurations
- Quick change leveler roll module
- Process metal strip up to 96” wide
- Gauge range 0.005”-0.100”
- Anti-Cross-bow Roll to remove unwanted crossbow induced in the strip
- The motors incorporate “regenerative drive” capabilities, meaning they have the ability to generate electricity that is then used to supplement the energy required for the exit bridle drive motors. This greatly reduces the energy costs to operate the system.
- Exit Pinch Roll System to generate required leveling tension without utilizing power from the recoiler
- Shape measurement systems to monitor shape and automatically control elongation based on the input specifications
- Entry uncoiler
- Exit recoiler
- Slitter or edge trimmer with scrap choppers
- Solvent spray system for reducing oxidation buildup
Machine Concepts offers new tension leveling cassette modules tailored to your needs, as well as module reconditioning services.
Module Disassembly, Inspection & Rebuild
The typical scope of rebuild work by Machine Concepts includes, but is not limited to the following:
- Leveler module cassette is disassembled, cleaned and critical dimensional references (diameters, roll locations, shaft dimensions, hardness, etc.) are documented and recorded.
- The cassette parts are labeled and laid out in an orderly fashion to assist in quick retrieval.
- Unit bases are clamped down and checked for flatness at all bearing pedestal locations, and the results are recorded.
- Customer-supplied drawings are used for reference in the rebuilds.
All rolls will be reused if the following conditions are met:
- Roll surface finish is acceptable
- Hardness is within original specification
- Roll diameters are acceptable for the whole set
All roll diameters are recorded and documented. Any roll with low hardness will be replaced. After a review of all diameters, a decision will be made on the allowed diameter to cut off.
All rolls will use no more than .020” under nominal as the guideline for replacement. This will be confirmed with the customer.
After all roll diameter dimensions are known, a final determination will be made as to how many rolls will be replaced. All roller bearings are to be replaced throughout the cassette.
BEFORE
Tension leveler cassette modules before disassembly and cleaning:
AFTER
Reconditioned tension leveler cassette modules:
Customer Success Story
