Revolutionizing Thin-Gauge Metal Fabrication: Certified Refurbished 1350mm Six-High Precision Leveling & Flying Shear System
*Siemens Digitalization Platform Delivers Micron-Level Accuracy with 50% Capital Expenditure Reduction*
Integrated Processing Capabilities
Material Versatility: Processes 1350mm wide coils across ferrous and non-ferrous substrates including stainless steel (304/430), aluminum alloys (1000/3000 series), and copper strips (C11000), accommodating 0.3–3.0mm thickness without mechanical reconfiguration
Flattening Excellence: 19-roller six-high architecture driven by 90kW power unit achieves ≤0.5 I-unit flatness certification per EN 10131 standards
Dynamic Cutting Precision: 150kW direct-drive servo shear system maintains ±0.1mm dimensional stability at 120 cycles/minute during continuous operation
Adaptive Control Ecosystem: Siemens S7-1500 PLC with 15" Touch HMI enables cloud-based recipe management and remote diagnostics
Seamless Transition Technology: Automatic thickness detection via laser sensors eliminates inter-gauge adjustment downtime
Engineering Breakthroughs
Intelligent Shearing Module
Blade Longevity: Vacuum-treated tungsten carbide cutters (HRC 62-65) sustain operational sharpness through 25,000+ cutting cycles under ISO 9001 monitoring
Deformation Prevention: Real-time servo synchronization compensates for material elastic recovery at acceleration rates up to 3.8 m/s²
Pattern Flexibility: Library stores 50+ geometric profiles including trapezoidal segments, notched patterns, and custom contour cuts with 0.1° angular resolution
Multi-Roll Leveling Superiority
Surface Perfection: Achieves 0.15mm/m flatness variance on 3mm 304 stainless through intermesh roll optimization
Pressure Intelligence: Closed-loop hydraulic system dynamically adjusts 50–800 ton leveling force based on material yield strength analytics
Vibration Control: Multi-axis active dampeners suppress resonance frequencies above 85 Hz during peak-speed operation
Siemens Industry 4.0 Integration
Production Visibility: WinCC SCADA provides real-time OEE tracking with automated shift reporting
Predictive Reliability: MindSphere IoT algorithms forecast component failures 300 operating hours in advance, reducing unplanned downtime by 30%
Motion Accuracy: Sinamics S120 servo drives ensure ±0.05mm positional repeatability across 10 million cycles
Energy Intelligence: G120 power modules with regenerative braking cut consumption to 0.38 kW·h/kg - equivalent to 25% reduction versus conventional drives
Certified Restoration Protocol
◉ OEM-Compliant Refurbishment:
Component Integrity: Magnetic particle/FPI inspection of all load-bearing elements per ASTM E1444/E1417
Geometric Precision: CNC roll regrinding achieves ≤0.003mm radial runout with surface roughness Ra 0.2μm
Control Modernization: Full S7-1500 retrofit including Profinet communication nodes and safety relay upgrades
Validation Testing: 72-hour continuous simulation processing 3mm stainless at 100% design capacity
Quality Assurance: ISO 9001:2015 certification with traceable calibration records for all critical subsystems
◉ Operational Readiness Package:
Three sets of pre-mounted shear blades (D2 tool steel, cryogenically treated)
Roller surface micro-hardness maintenance kits (60-65 HRC specification)
Siemens backup modules including SM521 digital input and SM322 output cards
Validated Production Economics
| Material Specification | Throughput Capacity | Line Speed | Dimensional Tolerance |
|---|---|---|---|
| 0.5mm AA1100 Aluminum | 18 metric tons/hour | 240 m/min | ±0.08 mm |
| 1.5mm C1100 Copper | 14 metric tons/hour | 180 m/min | ±0.10 mm |
| 2.0mm DX51D Galvanized | 22 metric tons/hour | 120 m/min | ±0.12 mm |
| 3.0mm SUS304 Stainless | 16 metric tons/hour | 85 m/min | ±0.15 mm |
Strategic Operational Advantages
| Performance Metric | This Refurbished Line | New Equivalent | Competitive Benefit |
|---|---|---|---|
| Capital Investment | $480,000 | $950,000+ | 50% immediate savings |
| Installation Timeline | 15 business days | 5–7 months | 10× faster commissioning |
| Operational Cost | $23/ton | $41/ton | 44% lower running cost |
| Energy Consumption | 0.38 kW·h/kg | 0.51 kW·h/kg | Annual $28,500 savings* |
| ROI Period | <18 months | 36–48 months | 2.5× faster payback |
| *Based on 6,000 annual operating hours at $0.12/kWh |
Comprehensive Support Infrastructure
Pre-Deployment Engineering Services:
On-site material trials with dimensional verification reports
Digital twin simulation for batch optimization using Siemens NX
Facility integration analysis including power distribution schematics
Post-Installation Assurance Program:
24/7 remote diagnostics via encrypted MindSphere portal
Priority air freight for critical components (72-hour delivery guarantee)
Biannual preventive maintenance including laser alignment verification
24-month warranty on all Siemens automation components
40-hour certified training: HMI programming, fault diagnosis, safety protocols
Global technical network:
