Jiade Machinery Tension Leveler Series

Xiangyang Jiade Machinery Co., Ltd. offers a comprehensive range of tension Levelers (stretch-bending levellers) tailored for diverse metal strip processing lines, including carbon steel, stainless steel, aluminum, copper, and titanium strips. Our product series covers 2-Bend 2-Straighten (Dry/Wet), 2-Bend 1-Straighten, and 3-Bend 2-Straighten configurations, all designed to eliminate yield platforms, remove scale, and achieve superior flatness (reducing strip flatness from ≤30–50 I to 3–5 I).

1. 2-Bend 2-Straighten Tension Leveler (Dry Type)

The dry-type configuration operates without liquid coolant/lubricant spray, relying on air purging and dry friction control. It is ideal for continuous annealing lines, color coating lines, and rewinding lines where surface moisture or oil residue must be avoided.

· Structure: Two pairs of bending cassettes (upper/lower) plus two pairs of straightening cassettes provide dual-stage plastic deformation and stress equalization.

· Features: Integrated hydraulic cassette quick-change system (optional), high-rigidity integral frame, and upper cassette fast-open for weld seam passage. It handles strip thickness 0.15–4.0 mm and speeds up to 600 m/min.

· Advantage: No effluent treatment required; minimized surface contamination; suitable for temperature-sensitive coatings.

2. 2-Bend 2-Straighten Tension Leveler (Wet Type)

The wet-type unit incorporates a spray lubrication/cooling system (water-based or emulsion) on the strip and rollers to reduce friction, lower surface temperature, and improve zinc/paint adhesion in galvanizing lines.

· Application: Widely used in continuous hot-dip galvanizing (CGL) and pickling lines to enhance descaling efficiency and prevent zinc powder buildup.

· Features: Stainless or hardened alloy spray nozzles with adjustable angle/height, sealed housing with dust/liquid collection, and corrosion-resistant roller options.

· Advantage: Extended roll life due to cooling/lubrication; smoother surface finish; higher line speeds with reduced roller wear.

3. 2-Bend 1-Straighten Tension Leveler

A compact and cost-effective configuration consisting of two bending units (front/rear) and one central straightening unit. This is the most widely adopted layout in general cold-rolling and finishing lines.

· Mechanism: The first bend introduces controlled plasticity, the second adjusts curvature distribution, and the single straightening roll eliminates residual transverse/longitudinal curvature.

· Features: Hydraulic up/down adjustment of lower cassettes, quick-open cylinders for welds, and optional wet/dry conversion capability.

· Application: Suitable for medium-thickness strips (0.15–3.0 mm) with moderate flatness requirements, such as general carbon steel, aluminum, and stainless steel finishing lines.

4. 3-Bend 2-Straighten Tension Leveler

An advanced, high-correction-capacity configuration with three bending units and two straightening units, delivering multiple alternating bend-straighten cycles within a short process section.

· Performance: Generates larger and more uniform elongation with only 1/3–1/5 of the pure tension required by pure stretch levelers, making it capable of correcting severe wave, buckle, coil break, and cross-bow defects in hard or ultra-thin strips (down to 0.03 mm for titanium/copper alloys).

· Features: Enhanced frame stiffness, precision absolute encoder-controlled lift for wrap-angle adjustment, and multi-stage cassette positioning for asymmetric bending strategies.

· Application: High-end automotive plates, silicon steel, precision alloy strips, and ultra-thin foil lines where flatness ≤3 I is demanded.

All Jiade tension levelers share core advantages: modular cassette design (one-in-use + one-standby), oil-filled maintenance-free backup rollers, in-machine scale suction collection, and compatibility with automatic extension-rate control via PLC + inverter drives. They serve major steel groups (Baowu, Ansteel) and export globally.

FRQ For Jiade Tension Leveler

I. Process & Performance (Addressing "Can it flatten the strip effectively?")

Q1: To what degree can your equipment improve flatness?

Jiade: For conventional mild steels (CQ/DQ grades), with elongation controlled within 0.5%~1.5%, we guarantee exit flatness stabilized at ≤5 I-Unit. For high-strength steels (e.g., SGH440 and above), we optimize the roll stack arrangement to stabilize flatness at ≤6 I-Unit. Our online shape meter provides closed-loop feedback to eliminate waviness and buckles in a single pass, meeting the stringent requirements for subsequent skin passing and painting.

Q2: Will Tension Leveling cause the zinc coating to flake off (powdering/spalling)?

Jiade: This is a core design priority for us. Firstly, our closed-loop tension control ensures tension precisely matches the yield strength, preventing over-stretching. Secondly, bending rolls feature high-precision grinding plus special surface treatment (chrome plating), maintaining roughness (Ra) below 0.8μm to minimize mechanical scraping of the zinc layer. Finally, real-time elongation monitoring triggers immediate alarms if limits are exceeded, eliminating coating damage at the source.

Q3: What thickness range can you handle? Can it process high-strength steel?

Jiade: Our standard models cover material thickness from 0.15mm to 6.0mm, with a maximum width of 1850mm. For high-strength steels, we equip the machines with high-power variable frequency motors and a high-strength roll system (with roll diameters increased by 20%) to ensure sufficient tension capability. For instance, our unit at a Shandong steel plant (Continuous Galvanizing Line) processes materials with a yield strength of 600MPa, operating with great stability.

Q4: Is adjustment convenient when changing product specifications?

Jiade: Very convenient. We utilize electric screw-down combined with hydraulic locking mechanisms, paired with one-touch preset functions on the HMI (Human-Machine Interface). During roll changes or grade changes, operators simply input the new specs on the touchscreen, and roll gaps and tension are automatically pre-set. Skilled operators can complete online fine-tuning within 3~5 minutes without stopping the line.

II. Line Integration (Addressing "Can it fit into our line?")

Q5: Can the speed match our current galvanizing line?

Jiade: Our design accommodates a maximum mechanical speed of up to 750m/min (customizable to your actual line speed), with motors and drive systems featuring a 15% operational margin. At your current operating speed of 250m/min, the equipment runs efficiently under low-load conditions and will not become a bottleneck for the production line.

Q6: In old line renovations, what if space is insufficient?

Jiade: We have extensive experience in old line upgrades. For space-constrained scenarios, we offer compact layout solutions (such as integrating the bending and straightening roll units) or optimized entry/exit looping strategies (looper towers). We provide free on-site surveying by engineers and deliver 3D layout drawings to ensure seamless integration into your existing line.

Q7: How stable is the tension control? Is there a risk of coil breaks?

Jiade: Extremely stable. We employ fully digital AC/DC drive control. Entry and exit bridle rolls are driven by independent Siemens or ABB inverters, working in conjunction with high-precision tension sensors (e.g., HBM brand) to achieve constant tension control with fluctuation margins within ±2%. Additionally, the equipment features a coil break protection system; upon detecting tension loss, the bridles stop within milliseconds to prevent equipment damage.

III. Reliability & Maintenance (Addressing "Will it minimize downtime?")

Q8: How long do the Work Rolls last? Is changing them troublesome?

Jiade: Under normal operating conditions, specially treated work rolls typically last 6~12 months. We have designed rapid roll change devices (e.g., rail-type transfer cars), eliminating the need for overhead cranes. A roll change requires only two operators and takes approximately 30~45 minutes, significantly reducing downtime for maintenance.

Q9: Can the equipment withstand the moisture and alkaline mist in galvanizing lines?

Jiade: The equipment is specifically protected for the galvanizing environment. The frame utilizes heavy-duty welded steel structures with anti-rust paint. All motors, encoders, and limit switches feature IP65 or higher ingress protection. Electrical cabinets are equipped with positive pressure ventilation systems and anti-corrosion air filters to shield internal components from acidic and alkaline gases.

Q10: Is daily maintenance complicated?

Jiade: Maintenance is straightforward. We incorporate centralized lubrication systems for timed and quantified greasing. Key bearing housings are fitted with temperature and vibration sensors, which can be integrated into your MES for predictive maintenance. We also provide detailed Maintenance Manuals and annual service schedules.

IV. Commercial & Service (Addressing "Is it cost-effective and reliable?")

Q11: Do you have references for similar galvanizing line projects?

Jiade: Yes. Projects such as the DRAPL (Direct Rolling Annealing Pickling Line) for stainless steel at Tsingshan Digital Technology are among our successful cases. I can share on-site operation videos, and if convenient, we can arrange a visit to a nearby site (subject to the owner's approval).

Q12: What are the delivery and commissioning timelines?

Jiade: The typical delivery period for a tension leveler is 4~5 months. We strive to align with your annual maintenance or renovation schedule. On-site installation and commissioning take approximately 2 weeks, covering both cold and hot commissioning to ensure rapid production startup.

Q13: How is warranty and after-sales service guaranteed?

Jiade: We offer a 12-month warranty (or 18 months after start-up, whichever comes first). Non-human-induced damages during the warranty period are repaired or replaced free of charge. Core components (e.g., gearboxes, PLCs) are sourced from top-tier international brands with global warranties, ensuring easy procurement.

V. Galvanizing-Specific Value-Adds

Q14: How do you balance elongation with zinc layer adhesion?

Jiade: We implement a "Low Tension, High Bending" philosophy. Compared to relying solely on high tension for flattening, we optimize the bending roll diameter and penetration depth. This achieves the same flattening effect at lower tension levels, significantly reducing the risk of damaging zinc layer adhesion. Furthermore, our process package includes a database of optimal parameters for different steel grades and coating thicknesses, ready for direct application.

Q15: Is the equipment easy to clean (to prevent alkali residue)?

Jiade: Note: This applies specifically to our Tension Leveling Scale breakers. Considering the alkaline spray in the pretreatment section, we have designed large-slope drip pans and drainage outlets at the machine base to prevent corrosive liquid accumulation. Roll cleaning utilizes a combination of high-pressure air knives and scrapers to ensure no residual alkali solution is carried into the zinc pot area.