Abstract: Dual-stage multi-roll leveler embodiments of the general inventive concept include independent sets of first stage work rolls and second stage work rolls, with each set of work rolls including one or more upper work rolls disposed above one or more lower work rolls. An adjustable but equal entry side-to-exit side gap is present between the upper and lower work rolls of each work roll set. An exemplary dual-stage leveler removes shape defects and coil set and/or curl from a moving strip material through a combination of work roll gap adjustment and first and/or second stage work roll bending. Because there is no feathering out of work roll penetration in either stage, differential roll speed and the problems associated therewith are eliminated.

Abstract: A dual-stage multi-roll leveler and an associated dual-stage work roll assembly. The dual-stage work roll assembly includes independent sets of first stage work rolls and second stage work rolls, with each set of work rolls including one or more upper work rolls disposed above one or more lower work rolls. An adjustable gap is present between the upper and lower work rolls of each work roll set, with the gap being equal from the entry side to the exit side thereof. A dual-stage leveler employs such a work roll assembly to remove shape defects from a moving strip material in the first stage and to remove coil set and/or curl from the strip material in the second stage, through a combination of work roll gap adjustment and first stage work roll bending. Because there is no feathering out of work roll penetration in either stage, differential roll speed and the problems associated therewith are eliminated.

Abstract: Devices, systems and methods for detecting the shape of a moving strip of material with high resolution along the edges thereof. Device and system embodiments may include a plurality of displacement-type shape sensor assemblies that may be collectively linearly displaced in a direction substantially transverse to the direction of a moving strip of material being examined, and also selectively activated or deactivated as necessary so as to provide edge-to-edge strip coverage to the extent possible.

Abstract: A system and method for cleaning the work rolls of a multi-roll leveler. The system includes a roll cleaning drive system for driving one or both of a set of upper and lower work rolls against a cleaning pad placed therebetween. The roll cleaning drive system is disengageable with the work rolls to be driven thereby. The upper and lower work rolls are driven in opposite rotational directions so as not to eject the cleaning pad from the leveler. The rotational direction of the upper and lower work rolls may be periodically reversed to produce a scrubbing action on the work rolls.

Abstract: A non-contact shape sensor and shape sensing device employing a plurality of such sensors. A non-contact shape sensor of the present invention may include a fluid-emitting sensor head that is biased toward a surface of a moving strip of material by a linear actuator. Pressurized fluid emitted from said fluid-emitting sensor head forms a cushion that causes said strip of material to remain separated from and glide over said fluid-emitting sensor head without actual contact therewith. A linear displacement sensor is associated with each non-contact shape sensor to measure the linear displacement of its fluid-emitting sensor head by said linear actuator in response to a loose section of said strip of material passing by said fluid-emitting sensor head.

Abstract: A non-contact shape sensor and shape sensing device employing a plurality of such sensors. A non-contact shape sensor of the present invention may include a fluid-emitting sensor head that is biased toward a surface of a moving strip of material by a linear actuator. Pressurized fluid emitted from said fluid-emitting sensor head forms a cushion that causes said strip of material to remain separated from and glide over said fluid-emitting sensor head without actual contact therewith. A linear displacement sensor is associated with each non-contact shape sensor to measure the linear displacement of its fluid-emitting sensor head by said linear actuator in response to a loose section of said strip of material passing by said fluid-emitting sensor head.

Abstract: A drive system for a multi-roll leveler. The drive system is coupled to a set of upper work rolls of the leveler. Preferably, the lower, and not the upper set of work rolls provide the bending necessary to flatten the strip of material. The drive system employs a gearbox housing one or more gear trains adapted to rotationally drive the upper set of work rolls. A drive means is coupled to the gear train(s). When more than one gear train is used, the gear trains may drive an equal or unequal number of upper work rolls. The upper work rolls may be splined to better engage the gear train. Output shafts may be provided on the gear box to connect the gear train(s) to the work rolls. The drive system does not require the use of universal joints to drive the work rolls. When the upper and lower sets of work rolls are contacted with the strip of material, the driven rotation of the upper work rolls causes the strip of material to move through the leveler.

Abstract: A displacement-type shape sensor for detecting the flatness of a strip of material. A flatness detection system may be formed from a plurality of said sensors. The displacement-type shape sensor preferably employs a roller bearing coupled to an actuator. A linear displacement sensor is coupled to the actuator/roller bearing to measure linear displacement. Preferably, the displacement-type sensor(s) is located below the strip of material and placed in contact therewith by movement of the actuator. By measuring the amount that the roller bearing(s) is displaced, it is possible to detect the flatness of the strip. Through use of a plurality of such sensors, areas of varying tension and, thus, areas of differing flatness of the strip of material may be detected. The displacement-type shape sensor may be used in conjunction with a precision leveler to effectuate leveling of the strip of material.

Abstract: A cassette assembly for a multi-roll leveler and a method for producing necessary work roll bending in such a cassette assembly. An upper and lower cassette module are provided for placement into a precision leveler. The lower cassette module is provided with roller support arms that lie below and transverse the work rolls of the module. The roller support-arms are pivotally connected to the lower cassette module near one side thereof. An actuator, or actuators, are integrally located in the lower cassette module to provide an upward force near the ends of the roller support arms opposite that of the pivotal connection. The upward force of the actuator(s) causes a resultant upward displacement of the roller support arms, and a corresponding bending of the work rolls of the lower cassette. The movement of the actuator(s) may be controlled and/or monitored by an automatic shape control system portion of the leveler to which the cassette assembly is installed.

Abstract: A quick change cassette system for a multi-roll leveler, such as may be used to flatten strips of material. The quick change system is designed for use with a leveler having an upper and lower cassette assembly containing upper and lower work rolls, respectively. The quick change system is also particularly suited for use with a lower work roll cassette that is mounted to the leveler in a hanging arrangement. A cart is mounted to the bottom side of the lower work roll cassette. Wheels are attached to a bottom portion of the cart to guide the cart into and out of the work envelope of the leveler along a set of guide rails. The cart can be moved manually or by means of a motor, cylinder, or other actuator. The cart remains attached to the lower work roll cassette during operation of the leveler. An upper work roll cassette may also be removed or installed to the leveler along with the lower work roll cassette.

Abstract: An automatically controlled multi-roll precision leveler for flattening a strip of material, such as a metal strip. A metal strip product may be fed into the leveler, typically from a coil. The leveler uses multiple work rolls to flatten the strip as it passes through a leveling section of the leveler. Upon exiting the leveling section of the leveler, the metal strip product passes over a shape sensor. The shape sensor may be divided into a plurality of individual measurement zones, each having one or more measurement segments. The shape sensor measures the shape error in the metal strip, which shape error is the result of stresses present in the strip. The shape error measurements are used by the shape control system of the leveler to automatically and continuously adjust the leveling parameters of the leveler. The control system attempts to operate the leveler, such that a shape error measurement of zero will be detected by the shape sensor—at which point the metal strip product will be flat.