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Primary Components and Functions of the Production Line
A complete four-roll double-sided plate grinding production line typically consists of the following sequential units:
1. Uncoiler
Function: Used to hold and unroll metal coils awaiting processing.
Features: Usually equipped with a hydraulic mandrel that automatically centers and synchronizes with the production line speed.
2. Traction Leveler
Function: Performs preliminary straightening before the sheet enters the grinding machine, eliminating inherent coil curvature and internal stresses to ensure the sheet enters the grinding zone flat. This is a critical prerequisite for uniform grinding results.
3. Core Equipment: Four-Roll Double-Sided Grinding Machine
Function: The “heart” of the production line. Here, the upper and lower surfaces of the sheet are ground by high-speed rotating abrasive belts.
Key Components:
Contact Rollers: Rollers encasing the sanding belts that press directly against the sheet. Their material (typically polyurethane or rubber) and hardness determine the aggressiveness of the grinding action.
Sanding Belts: Selected and replaced based on the desired final surface finish (e.g., 180-grit, 240-grit, 320-grit, etc., corresponding to different levels of grain texture).
Tensioning System: Maintains proper belt tension for stable grinding.
Pressure System: Precisely controls the grinding roller's pressure on the sheet. Higher pressure increases material removal rate.
Cooling System: Sprays specialized coolant (emulsion) onto the grinding zone to reduce temperature, flush away swarf, prevent sheet overheating/warping, and avoid belt clogging.
4. Cleaning and Drying System
Function: Thoroughly removes metal powders and coolant residue adhering to the surface after grinding.
Process: Typically includes pre-rinse → brushing → high-pressure spray → drying (using high-pressure blowers or hot air dryers). Inadequate cleaning may cause issues in subsequent processes (e.g., film coating) or lead to staining during storage.
5. Film Coating Machine
Function: Immediately applies a protective film to the pristine surface after cleaning and drying, preventing scratches during transportation, storage, and subsequent processing.
6. Tension Control and Web Guiding System
Function: This serves as the central nervous system ensuring continuous, stable production line operation. Multiple photoelectric or hydraulic sensors monitor web deviation and tension in real time during transport, automatically adjusting roller speeds and tension to prevent wrinkling, tearing, or scratches from misalignment.
7. Rewinder
Function: Rewinds processed sheets into rolls for convenient transportation and storage.
Features: Equipped with automatic centering and precise tension control to ensure neat, compact winding.
