Leveraging Siemens Control for Unmatched Efficiency in Metal Processing
This professionally refurbished Yawei production line integrates a high-performance flying shear line and a second-hand 6-Hi roller leveler to deliver precision cutting and leveling for sheet metals up to 1350mm width and 0.3–3.0mm thickness. Manufactured by Yawei and renewed to 90% new condition, the system targets industries requiring aerospace-grade tolerances, such as automotive and construction. At its core sits the Siemens control ecosystem—based on SIMATIC S7-1500 PLC and SINAMICS G120 drives—enabling real-time adjustments, predictive maintenance, and seamless automation. With a focus on sustainability, this solution offers 50% capital savings versus new equivalents while achieving ±0.3mm cutting accuracy and ≤1.5 I-units flatness. Key applications include processing stainless steel, aluminum, and carbon steel, with throughput speeds up to 120 m/min.
The system comprises three synergistic modules, each optimized for reliability and performance.
Material Handling: Processes diverse metals including stainless steel (e.g., 430 grade), carbon steel (e.g., DP780), and aluminum alloys, with width fixed at 1350mm for standardized outputs.
Energy Efficiency: The flying shear line incorporates regenerative drives, recovering 90% energy during deceleration, while the second-hand 6-Hi roller leveler reduces power draw via optimized roll pressure.
The integration of Siemens control elevates this refurbished system beyond conventional lines.
Flying Shear Line Dynamics:
Hydraulic-assisted synchronization eliminates stoppages during cutting, achieving burr-free finishes (surface roughness Ra ≤1.6 μm) even at 120 m/min line speeds.
Laser-guided alignment minimizes edge trim loss to ≤0.5%, translating to annual material savings of ~50 tons for high-volume facilities.
Siemens control enables adaptive speed matching, allowing the flying shear line to handle variable thicknesses without manual intervention.
Second-Hand 6-Hi Roller Leveler Superiority:
The cascaded roll design (entry: 8 rolls → intermediate: 5 rolls → exit: 6 rolls) applies progressive pressure to eliminate defects like crossbow in thick plates (up to 3.0mm).
Roll surfaces are hardened to HRC 62 via OEM-grade refurbishment, ensuring 10,000+ operating hours durability.
Siemens control facilitates real-time gap adjustments (±0.01mm), correcting for material inconsistencies during high-speed runs.
Siemens Control Ecosystem:
Real-time monitoring via the 21.5" HMI provides thickness profile visualization and diagnostics, reducing setup time by 40%.
Predictive maintenance algorithms (integrated with TIA Portal) generate alerts for potential failures, cutting downtime by 30%.
The system stores multiple cutting recipes, enabling instant changeovers for batch production—ideal for just-in-time manufacturing.
This flying shear line and second-hand 6-Hi roller leveler combination excels in operational metrics, validated through ISO-certified testing.
Economic Impact: With a <18-month ROI, the second-hand 6-Hi roller leveler reduces operating costs to 41/ton for new lines), while the Siemens control system ensures 70% retained resale value.
Sustainability Edge: Component reuse rates hit 85%, lowering carbon footprint by 30% versus new manufacturing.
The flying shear line and second-hand 6-Hi roller leveler serve critical roles across high-demand sectors, with Siemens control enabling seamless adaptation.
Automotive: Processes 1.2mm DP780 steel for door panels and chassis parts, achieving ±0.05mm flatness to eliminate post-forming defects.
Construction: Handles 3.0mm aluminum alloy sheets (1350×6000mm), enabling rapid shearing for structural components with burr-free edges.
Appliances: Cuts and levels 0.5mm 430 stainless steel for sinks and housings, reducing scrap rates by 15% through precision tolerance.
Emerging Sectors: Ideal for renewable energy (e.g., solar panel frames) and aerospace, where Siemens control ensures compliance with ISO 9001 standards.
Yawei’s refurbishment protocol guarantees reliability, backed by comprehensive Siemens control-centric services.
Pre-Sales Support: Free material trials on the flying shear line and integration planning for existing facilities.
Post-Sales Commitment:
12-month warranty covering all critical components, including emergency spare parts (e.g., blades, sensors).
30-hour certified training on Siemens control troubleshooting, with multi-language manuals.
Technical Support: 24/7 remote diagnostics via Siemens portals; 72-hour critical parts delivery global network.
Upgrade Options: Optional Yawei SmartShear™ package adds AI defect detection, enhancing the second-hand 6-Hi roller leveler’s capabilities for Industry 4.0 integration.
