Fully Automatic Straightening Machine — Autonomous Flatness at Production Speed

Autonomous Flatness at Production Speed

Monotech Engineers Pvt. Ltd. presents the Fully Automatic Straightening Machine engineered to correct coil set, cross bow, and edge wave on mixed quality scrap sheets and strips with minimal operator input. A high stiffness frame, precision ground work rolls, and a PLC/HMI driven automation suite with servo penetration and sensor feedback deliver repeatable flatness, high throughput, and full traceability for service centers and fabrication lines. Available for widths 300–1600 mm and thickness ranges 0.5–8 mm (MS), with custom models for stainless, aluminum, and high strength grades, turnkey lines include decoiler, loop control, servo feeder, shear, and stacking automation to streamline end to end processing.

Design & Construction

Automation core: Industrial PLC/HMI runs closed loop control of roll penetration, crown compensation, speed, and pass schedules; one touch recipe start triggers an auto threading sequence to minimize setup time and scrap.
Work roll cassette: 7/9/11 precision ground, induction hardened alloy steel rolls with synchronized entry/exit pinch rolls ensure stable feeding and contact; optional chrome finish supports coated stock.
Backup system: Multi row backup bearings beneath each work roll limit deflection to preserve flatness uniformity across the strip width, enhancing downstream quality.
Drives: An electro mechanical main drive with helical gearbox and VFD maintains consistent surface speed, while servo actuators position penetration and left/right crown trim with high repeatability.
Structure: A stress relieved welded frame with heavy side plates and tie bars reduces vibration and supports long term geometric accuracy under continuous duty.
Sensors: Load/current monitoring with optional laser or roller flatness sensing at exit, entry edge guides, and loop control provide the inputs required for fully automatic pacing and adaptive correction.

What Makes Our Design Unique?

One touch flatness: Auto mode selects penetration curves, speed, and crown from the recipe and adapts using feedback to handle scrap variability without frequent operator intervention.
Quality assurance: The HMI logs flatness settings, alarms, production counters, and energy data, enabling batch wise traceability and continuous improvement.
Surface preservation: Polished, hardened rolls and an optimized wrap path limit print through; chrome rolls and PU pinch options further protect sensitive surfaces.
Rapid changeovers: Recipe management with barcode/ID recall, teach mode capture, and automatic roll back to safe position accelerates threading, maintenance, and repeat jobs.

Key Features & Accessories

Performance driven productivity

Auto threading: Sequenced pinch/feeder motions and edge guide alignment reduce start up time and material waste for each batch.
Adaptive control: Closed loop servo penetration and independent left/right crown trim mitigate edge wave and center buckle dynamically during production.
Line pacing: Coordinated speed control links decoiler, loop, feeder, shear, and stacker to sustain continuous throughput and stable flatness.
Safety: Dual channel E stop, light curtains or safety rope, interlocked guards, overload protection, and safe torque off drives protect operators while preserving uptime.

Optional accessories

Complete Cut To Length line: Motorized decoiler with hydraulic mandrel, loop pit or dancer, servo feeder, flying or guillotine shear, magnetic/air blast part ejection, and stacker with alignment for turnkey automation.
Quick change cassette: Tool less roll cartridge removal supports polishing and alternate roll sets for different materials and finishes.
Advanced flatness sensor: Laser array with automatic correction table generation by material/width tightens tolerance control and shortens dial in time.
Remote connectivity: Secure diagnostics, recipe backup/restore, and predictive maintenance alerts enhance responsiveness and OEE tracking.

Control & Handling

HMI Workflows: User-friendly interface with material selection and recipe management for thickness, yield, crown, passes, and speed. Live charts track load, flatness, and energy use, with alarm history and maintenance scheduling.
Assisted Setup: Auto-recommendations for crown and penetration based on material properties; teach mode stores proven parameters for quick reuse.
HMI Workflows: User-friendly interface with material selection and recipe management for thickness, yield, crown, passes, and speed. Live charts track load, flatness, and energy use, with alarm history and maintenance scheduling.
Assisted Setup: Auto-recommendations for crown and penetration based on material properties; teach mode stores proven parameters for quick reuse.
Recipe Management: Pre-set and recallable material recipes ensure consistency and reduce setup time.
Remote Monitoring: Secure connectivity for live diagnostics, alarm logs, and predictive maintenance alerts.
Training & SOPs: On-site commissioning, safety sessions, operator/maintenance SOPs, and QA documentation templates ensure safe, consistent adoption.
Error-proofing & Safety: Interlocks, guided workflows, and alarm-driven prompts prevent operator errors and material damage.
Data and Analytics: Automatic logging of runs, deviations, and KPIs supports quality control and process optimization.
Operator Ergonomics: Intuitive multilingual touch interface with simplified navigation reduces fatigue and error

Why Choose Monotech’s Permanent Magnetic Lifting Magnet?

Highest flatness consistency on variable scrap through closed‑loop servo penetration and adaptive crown control, reducing rework and manual intervention.
Lowest operator dependency via one‑touch recipes, auto threading, and integrated line pacing that standardize quality across shifts.
Proven reliability and safety with industrial components, redundant interlocks, and rich diagnostics that support continuous duty and compliance.
Tailored turnkey delivery with decoiler‑to‑stacker integration, acceptance testing, and training to match plant layouts and throughput targets.

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