·Ultra-Long Structure Design
Maximum effective temperature control length reaches 16000mm with anti-sagging structure design. Ordinary temperature control rollers are limited by processing equipment and structural design, with effective length generally not exceeding 4200mm. Ultra-long rollers are highly prone to self-weight sagging combined with thermal deformation, causing transverse film thickness variation and web deviation. Variable-wall-thickness gradient forging structure with thickened central wall section optimizes force distribution. Three-stage stress release through quenching and tempering, low-temperature tempering, and extended vibration aging after rough machining maximizes residual stress elimination. Under 180–230℃ long-term constant temperature operation, central sagging deformation is controlled within 0.022mm, effectively resolving long-standing industry challenges on ultra-wide film and nonwoven production lines.
·Temperature Uniformity
Multi-circuit zoned composite spiral flow channel structure maintains temperature differential ≤±0.9℃ on ultra-long rollers (length >10000mm), eliminating cold edges at both ends and overheating in the center. When conventional single-spiral flow channels are applied to ultra-long rollers, the thermal medium continuously cools along the length direction, with axial temperature differential generally exceeding 2℃. Fluid dynamics simulation-optimized multi-pass reciprocating spiral heat exchange channels with multi-point inlet/outlet and full-range turbulent heat exchange balance heat loss compensation at both ends of ultra-long rollers. Achieves uniform heat exchange without external zoned temperature control modules, ensuring consistent heating conditions from left to right across ultra-wide materials, preventing film crystallization non-uniformity and transverse nonwoven bonding strength fluctuations.
·Integral Forging
Long-dimension integral forging process eliminates segmented welded seams, preventing weld stress concentration and long-term thermal cycle leakage risks. Ultra-long rollers on the market commonly use multi-segment shell welding, with inconsistent metallurgical structure in weld zones prone to deformation and internal leakage under repeated thermal cycling. Large alloy steel integral forging blank enables the entire roller to be integrally machined without weld seam weak zones. Internal flow channels are integrally deep-hole milled, providing stronger sealing pressure stability, with thermal oil or cooling water circulation systems maintaining 1.6MPa working pressure long-term, suitable for 24/7 year-round production in overseas factories.
·Dynamic Balancing and Operational Precision
G1.0 dynamic balancing grade with radial runout ≤0.004mm on ultra-long rollers, compatible with maximum line speeds of 320m/min. Ultra-long rollers have large length and high self-weight, with ordinary dynamic balancing processes unable to eliminate long-distance vibration, causing periodic vibration marks and material wrinkles at high speed. Segmented multi-point dynamic balancing calibration with integrally forged journals and roller body significantly enhances load-bearing stiffness. On ultra-thin films and lightweight nonwovens continuous processing, it effectively eliminates web flutter and periodic light-dark stripes, significantly reducing ultra-thin substrate scrap rates.
·Surface Treatment Versatility
Full spectrum of surface treatment options compatible with a single ultra-long temperature control roller, customizable to mirror, matte/satin, or anti-stick coating surfaces for preheating, cooling, and calendering multi-process applications. Unlike single-function rollers, after temperature control structure machining, the roller can undergo ultra-mirror polishing, CNC sandblasting matte treatment, hard chrome plating, or Teflon anti-stick coating. The same ultra-wide production line can switch surface treatments for cast film cooling, preheating sizing, and matte calendering processes, reducing spare roller investment and optimizing fixed asset costs.
·Long-Term Production Reliability
Weld-free integral forging eliminates weld corrosion and medium leakage failures, significantly reducing maintenance shutdown frequency. Stable temperature uniformity ensures high transverse product quality consistency, reducing thickness variation and poor lamination defects. Excellent thermal deformation control eliminates frequent shutdowns for roll parallelism calibration, improving line productivity. The tough substrate supports localized surface repair and re-chrome plating without complete roller replacement, with lower long-term operational costs.
·Line Flexibility
The same ultra-long temperature control roller flexibly adapts to both heating/constant temperature and cooling/sizing conditions, switching between thermal oil and cooling water media. Widely compatible with domestic, European, and Southeast Asian imported ultra-wide extrusion, casting, and nonwoven hot-rolling units. Journal, flange, and connection interfaces support non-standard modification matching without customer equipment frame modification.
English
