Equipment Positioning and Functions
This flattening and trimming machine is a key finishing equipment in the transformer fin production line, mainly used for correcting the flatness and trimming the edges of rolled or welded fins. It eliminates defects such as wave deformation and edge warping generated during the forming process, ensuring the dimensional accuracy and surface flatness of fins, and providing qualified workpieces for subsequent assembly (such as welding with transformer oil tanks). The equipment achieves integrated "flattening + trimming" operations through multi-roll leveling and edge pressing design, improving production efficiency.
Main Technical Parameters
|
Item |
Parameter |
Description |
|
Motor Power |
4kW |
Power source for driving the reducer and roller sets |
|
Processing Speed |
8m/min |
Linear speed of fins passing through the equipment |
|
Leveling Roll Diameter |
105mm |
Core component size of the leveling rolls |
|
Leveling Roll Configuration |
Upper 5 / Lower 4 |
Upper and lower rolls arranged in a staggered pattern to form leveling pressure |
|
Number of Edge Pressing Rolls |
5 pairs |
Quantity of edge trimming roller sets |
|
Roller Material/Hardness |
40Cr, surface quenched HRC48-52 |
Wear-resistant material suitable for long-term high-load leveling |
|
Transmission Mode |
Reducer-driven |
Gear reducer transmits torque for stable and reliable operation |
Core Structure and Working Principle
Leveling System
Roll Set Design
The upper 5 leveling rolls and lower 4 leveling rolls are arranged in a "triangular" staggered pattern. By adjusting the spacing between upper and lower rolls (adjustable range: 0~10mm), continuous bending stress is applied to the fins to eliminate longitudinal wave deformation and transverse bending.
The leveling rolls have a diameter of 105mm and a ground surface with a roughness of Ra≤1.6μm to avoid scratching the fin surface.
Correction Principle
When fins pass through the roll set, plastic deformation occurs during multiple forward and reverse bendings, homogenizing internal stresses in the material to finally meet the flatness requirement of ≤1.5mm/m (industry standard for transformer fins).
Edge Pressing and Trimming System
5 Pairs of Edge Pressing Rolls
Installed behind the leveling rolls and symmetrically arranged, they apply transverse pressure to both side edges of the fins to trim edge warping (such as welding flash and rolling burrs), while further calibrating edge straightness.
Roll Material
40Cr steel with surface quenching, hardness HRC48-52. Its wear resistance is superior to ordinary carbon steel, with a service life of over 5,000 hours and can be reused through grinding.
Transmission and Adjustment
Power Transmission
The 4kW motor drives the lower rolls to rotate via a gear reducer (speed approx. 120rpm), and the upper rolls rotate passively via friction. The stable transmission ratio ensures uniform leveling force.
Roll Spacing Adjustment
Equipped with a manual worm gear adjustment mechanism to quickly adjust the spacing between upper and lower leveling rolls, adapting to the leveling needs of fins with different thicknesses (e.g., 10~14mm plate thickness).
Equipment Advantages
Efficient Integrated Operation
1.A processing speed of 8m/min can match the production capacity of upstream rolling machines and welding machines (e.g., when the rolling machine speed is 14m/min, it can be synchronized via frequency conversion speed regulation) to achieve continuous assembly line operation.
2.Simultaneous completion of leveling and edge pressing reduces workpiece transfer steps, with a single machine capable of processing ≥80 fins per hour (calculated based on a fin length of 2m).
Durability and Easy Maintenance
1.The rolls use 40Cr quenching technology with high surface hardness and wear resistance. Under normal use, the grinding cycle is ≥2,000 hours, resulting in low maintenance costs.
2.The reducer uses oil bath lubrication with a replacement cycle of ≥6 months. The overall equipment structure is simple, and daily maintenance only requires checking roll surface cleanliness and lubrication status.
Strong Compatibility
1.Capable of processing various fin specifications with widths of 310~550mm and lengths of 700~4000mm. By adjusting the roll spacing and edge pressing roll spacing, product models can be quickly switched with a changeover time of ≤10 minutes.
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