Part levellers. Materials Steel Aluminium Copper Brass Special alloys Bimetallic

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1 PART LEVELLERS

2 Part levellers SOPREM levellers ensure your product quality. Distorted metal components are a thing of the past; today quality products are processed regardless of the source material. How do deviations in flatness occur? Deviations in flatness can occur during punching, laser or plasma cutting, hardening, nibbling, shearing and coating. They are caused by inner material tensions in components during processing. Your specifications are our benchmark. We manufacture quality equipment to meet your straightening requirements. We manufacture both SCHUBERT and SOPREM design levellers. The best straightening quality for a component part can only be determined by first using a straightening test from SOPREM. Parts spectrum The following component parts can be processed using our straightening equipment in SCHUBERT design: Parts with thickness from 0,05 up to 8 mm Parts with a width from 5 up to 630 mm Parts with a length of 2000 mm. Materials Steel Aluminium Copper Brass Special alloys Bimetallic Use Equipment building Mechanical and vehicle engineering, Electro technical parts Building industry products Sawing and cutting tools Drop wires Perforated metal plates

3 02 03 > 03 SCHUBERT design SOPREM build levellers in SCHUBERT design using the most modern drive and control technology. Advantages Large thickness ranges can be processed Narrow bend radii ensure a further elimination of the material inner tensions Features Each straightening roll is driven over a hinged shaft with roller axes distances being minimized and an optimum straightening geometry with minimum bending radii being achieved. Material inner tensions are reduced. Parts leveller with 19 rolls A parts leveller with 19 x 6 mm diameter leveller rolls is used to straighten material thicknesses from 0,05 up to 1mm. As an option, we offer automatic feed and ejection of parts. > 03 Parts leveller with 23 rolls A parts leveller with 23 x 45 mm diameter leveller rolls is used to straighten material thicknesses from 0,5 up to 8 mm. As an option, automatic feed and ejection of parts are available.

4 SCHUBERT design part leveller > 03 > 04 Straightening head The straightening head is the tool of the straightener. Its precision and rigidity is decisive for the quality and result of the straightening process. For adjustment of the straightening head, the straightening rolls are positioned using either by a hand operated or motor driven worm gear. > 04 Support of the straightener rolls as height adjustable As an option, we can design each roll support of the lower part of the straightener as height adjustable, which results in bending of the rolls, eliminating part inner waving. Motorised adjustment is available. This option is only possible with infeed widths from 630 mm. Drive Mostly speed-controlled drives are used. The power is transmitted to the power take-off gear using a gear belt; from here a hinge shaft drives each straightening roll. Distances between the roller axes are minimized in this way. > 03 Straightening rolls support A constant straightening and flattening profile is obtained by supporting the straightening rolls with supporting rolls. Bending of the straightening rolls during the straightening process is avoided in this way.

5 04 05 > 03 > 04 Conveyor belt The movement for feeding and discharging are specifically set for each part. Small parts are fed by conveyor belts. In-feed unit with part separating An in-feed unit with part separating can be retrofitted at the inlet of the straightener. By a conveyor belt the lowest part will be pushed trough a height adjustable rail to the machine. > 03 Turntable As parts have to be adjusted in two directions, a turntable is indispensable, if larger quantities are being produced. The parts are turned 90 and fed into the straightening equipment. > 04 Counter and measuring unit Equipment outlet with counter and measuring unit.

6 SOPREM design part leveller SOPREM design part levellers are hydraulically powered saving energy and preventing damage to mechanical parts, through only marginal wear and giving a longer life to the equipment. Your specifications are our benchmark. We build our equipment to meet your straightening requirements. The best straightening quality for a part can only be determined by first using a straightening test from SOPREM. Parts spectrum The following parts can be processed using our straightening equipment in SOPREM design: Parts with a thickness from 0,1 up to 4 mm Parts with a width from 5 up to 450 mm Parts with a length of 2000 mm Materials Steel Aluminium Copper Brass Special alloys Bimetallic Use Equipment building Mechanical and vehicle engineering, Electro technical parts Building industry products Sawing and cutting tools Drop wires Perforated metal plates

7 06 07 SOPREM design Part leveller with 19 leveller rolls, feed rolls and pivoting table to straighten perforated metal plates. The upper straightening head can be tilted in a longitudinal or cross direction. The straightening head is adjusted using a worm gear. Part leveller with 19 rolls This part leveller with 19 x 35 mm diameter leveller rolls is used to straighten material thickness from 0,5 up to 4 mm. Optionally we can offer automatic feed and ejection of parts. Advantages: Low cost part leveller Maintains material surface rigidity due to larger bending radii Features Each straightening roll is driven by a gear wheel, thereby achieving larger roller axes distances and larger bending radii.

8 SOPREM design part levellers > 03 > 04 Straightening head The straightening head is the tool of the straightening machine. Its precision and rigidity is decisive for the quality and result of the straightening process. The lower part of the straightener can be pulled out for easy cleaning of the straightening rolls. Transversal inclination of the roller bed Wavy edges of tailored blanks can be eliminated by transversal inclination of the roller bed. Transversal inclination occurs using either a hand operated or motor driven worm gear. > 03 Longitudinal inclination of the roller bed Most material bending occurs at the straightener insert, where the material becomes ductile. Longitudinal tilting of the roller bed is achieved using either by hand operated or motor driven. > 04 Straightener lower part to be pulled out

9 08 09 > 03 > 04 Motorised adjustment of straightening rolls The parameters are saved during motor activation of the straightening rolls. If the order is repeated, the appropriate program is selected and the leveller setting automatically moves to the programmed position. 10th straightening roll A 10th straightening roll can be fitted at the outlet of the straightener, which can be individually adjusted, thereby adding additional influence to the straightening quality. > 03 Feed table A feed table with photoelectric sensing barrier can be fitted at the inlet to prevent accidents. > 04 Pivot table A pivot table can be fitted at the outlet of the straightening machine.

10 Levelling tests Levelling tests as a first step With the straightening test we ensure, that you can achieve the required result. Every case is different and the combination of your straightening quality requirements with the material quality, the inner tension and the specific surface characteristics of a component part is almost always unique, which makes straightening tests indispensable. Our engineers will determine the most suitable straightening size and geometry. The diameter of the straightening rolls, the dimensions of the axes, the distance between the axes, the condition of the surface and the stiffness of the machine influence the straightening result. We offer 19- roll straighteners designed by SOPREM, as well as 19- and 23- roll straighteners designed by SCHUBERT. Remo Wicker, test engineer in the SOPREM laboratory: «With the straightening tests we determine the ideal straightening process. This way we achieve that the products are straightened in the required quality, and maintain their shape.»

11 R1 Levelling to achieve high efficiency. Straightening with 19 rolls R2 R3 R4 Detail A of pic 01 R1 R2 R thickness of material R1 R2 A R3 R4 thickness of material R1 R2 R3 R4 thickness of material > 03 Detail of pic 02 Bending R1 R1 R3 > 04 Detail of pic 02 Bending R2 R2 R4 thickness of material > 05 Detail of pic 02 Bending R3 zone of zone plastical of plastical deformation deformation > 06 Detail of pic 02 Bending R4 thickness of material Advantages Straightening will reduce interruptions and downtime during production, installation and further processing. Processing complexity for components, which have to be processed subsequently, will be reduced. Straightening provide the basis for high quality and cost effective edge finishing for welding They produce product accuracy Straightening disposes of visible bending and rippling of components Effects during straightening We achieve the highest flatness accuracy through roller straightening and reducing material inner tensions. Each of the driven straightening rolls adjusts the part by alternate bending. To achieve this, the upper and lower row of rolls is staggered and form wedged-shaped profiles, which open in the feed direction. Most bending of the material occurs at the inlet, where the material becomes ductile. Depending on the range between the upper and lower yield point, the plastic deformation takes place, more or less material inner tension can be achieved. As the optimum straightening quality can only be found empirically, our engineers will analyse your requirements first and then find the most suitable solution in a straightening test.

12 Straightener with 19 rolls in SOPREM-Design straightening rolls part thickness part width max. Max. capacity 19 ø 12 mm mm 160 mm mm 19 ø 16 mm mm 160 mm mm 19 ø 16 mm mm 250 mm mm 19 ø 16 mm mm 350 mm mm 19 ø 25 mm mm 200 mm mm 19 ø 25 mm mm 350 mm mm 19 ø 25 mm mm 450 mm mm 19 ø 35 mm mm 250 mm mm 19 ø 35 mm mm 350 mm mm 19 ø 35 mm mm 450 mm mm Straightener with 19 / 23 rolls in SCHUBERT-Design straightening rolls part thickness part width max. Max. capacity 19 ø 6 mm mm 85 mm mm 19 ø 9 mm mm 120 mm mm 19 ø 12 mm mm 150 mm mm 19 ø 18 mm mm 120 mm mm 19 ø 18 mm mm 220 mm mm 19 ø 24 mm mm 120 mm mm 19 ø 24 mm mm 260 mm mm 23 ø 30 mm mm 350 mm mm 23 ø 30 mm mm 630 mm mm 23 ø 45 mm mm 350 mm mm 23 ø 45 mm mm 630 mm mm SOPREM Automation AG Schlettstadtstrasse 4 CH-2540 Grenchen Switzerland Tel Fax info@soprem.ch