In the continuous operation chain of steel rolling, the flying shear is far more than a simple cutting device—it’s the critical link connecting rolling, finishing, and coiling processes. Its performance directly dictates production efficiency, material waste rates, and final product quality. A high-quality flying shear transforms production lines from “passive following” to “proactive efficiency enhancement.” Our advanced flying shear equipment is engineered to address industry pain points through comprehensive upgrades in technology, structure, intelligence, and service—emerging as a true “productivity engine” that delivers long-term value for enterprises worldwide.
1. Full-Scenario Deep Adaptability: Not Just “Compatible” – But “Optimized”
Rolling lines vary dramatically in process, material characteristics, and speed requirements. Ordinary flying shears often struggle with limited adaptability and cumbersome switching. Our flying shear achieves “seamless integration across scenarios” through modular design and parameter optimization:
- Universal Line Compatibility: Flexibly installable (left/right/central mounting) for pickling-cold rolling combined units, fully continuous cold rolling lines, galvanizing/color coating pretreatment lines, and silicon steel production lines. It handles strip thickness from 0.1mm to 3.0mm and width from 500mm to 1600mm, with a maximum shearing speed of 260m/min—perfectly matching rhythms from low-speed precision rolling to high-speed continuous rolling, eliminating bottlenecks like “rolling mill waiting for shearing” or “coiling waiting for materials.”
- Comprehensive Process Coverage: Beyond standard head/tail cutting (removing oxide scale and defective sections), fixed-length cutting (precision slitting by order length/coil weight), it supports dynamic slitting (real-time strip splitting at high speed), emergency cutting (rapid material separation during line jams or equipment anomalies to prevent accident escalation), and segmental cutting (multi-length requirements for special orders). Compatible with carbon steel, stainless steel, coated steel, silicon steel, and other materials—no core component replacement needed, just parameter adjustments for quick switching.
- High Material Elasticity: Built-in process database automatically matches shearing force, blade gap, and cutting speed for materials with tensile strength ≤850MPa. It avoids “material pulling or incomplete cutting” for thin strips (0.1-0.5mm), “blade chipping or strip deformation” for thick strips (2.0-3.0mm), and optimizes cutting angles for special materials like stainless steel to reduce work hardening.
2. Millimeter-Level Precision Control: From “Cutting Through” to “Cutting Precisely, Cleanly, and Economically”
Inadequate cutting precision is a major source of waste in steel rolling—dimensional deviations cause product scrap, excessive head/tail cutting wastes raw materials, and uneven shear surfaces increase finishing workload. Our flying shear achieves industry-leading precision through three layers of technical guarantees:
- Structural Precision Foundation: Adopts “roller-type blade arrangement + helical gear anti-backlash mechanism” for stable blade movement, eliminating dimensional fluctuations from mechanical gaps during shearing. The shear frame is welded from Q355B high-strength steel and stress-relieved via vibratory aging, with long-term operation deformation <0.1mm—laying the groundwork for high precision.
- Control Precision Assurance: Equipped with Siemens S7-1500 series PLC and full-closed-loop servo control system, with shear command response time <10ms and fixed-length precision up to ±0.5mm (surpassing the industry standard of ±1mm). High-precision encoders and proximity switches real-time feed back strip speed and blade position, achieving “speed synchronization, precise positioning, and smooth movement” to avoid cumulative errors.
- Shear Quality Excellence: Blades are made of H13 hot-work die steel with vacuum quenching (hardness HRC58-60) and precision grinding, resulting in shear surface roughness Ra ≤1.6μm—reducing edge burrs and tearing. Supports “automatic/manual dual-mode blade gap adjustment” (0.05-0.3mm adjustable), automatically matching the optimal gap for strip thickness to improve quality and extend blade life by over 30%, lowering tool replacement costs.
3. Reliable Durability + Intelligent Operation: Not Just “Long-Lasting” – But “Low-Maintenance”
Steel rolling lines operate 24/7, so equipment stability directly impacts capacity utilization, while maintenance costs are a key enterprise expense. Our flying shear excels in both “stability” and “maintainability”:
- Trusted Core Components: Critical transmission parts (gears, bearings) use international brands like SKF/FAG for superior wear and impact resistance. The 480kW DC motor (Model: FJDJ-45-532) features forced air cooling, operating at ≤85℃ continuously with a service life exceeding 80,000 hours. The electrical control system integrates high-quality components such as Schneider circuit breakers and Siemens DC drives, reducing failure rates by 40%.
- Comprehensive Intelligent Protection: Built-in multiple safety interlocks and fault early warnings—overload protection (automatic unloading when shear force exceeds thresholds), temperature monitoring (real-time motor/bearing temperature tracking with overheat alarms), blade wear warning (current-based blade status detection), and emergency stop (dual emergency cutoff via on-site buttons and remote control)—preventing equipment damage and safety incidents.
- Efficient Maintenance: Modular design allows easy replacement of wear parts (blades, bearings) without disassembling the entire unit, with replacement time ≤30 minutes (vs. 1-2 hours industry average). The equipment includes maintenance channels, inspection platforms, and observation windows for daily checks. Remote diagnostic capabilities enable technicians to monitor real-time data, quickly locate faults, and minimize downtime.
4. Tangible Cost Savings & Efficiency Gains: Every Flying Shear is a “Profit Driver”
The value of high-quality equipment ultimately translates to enterprise costs and revenues. For a cold-rolled strip line with an annual output of 500,000 tons, our flying shear delivers measurable benefits:
- Capacity Increase by 8%-12%: Seamless speed matching with rolling mills eliminates waiting time, adding 400-600 tons of daily output.
- Material Waste Reduction by 0.5%-0.8%: Precision cutting and optimized head/tail length (adjustable from 50-80mm vs. standard 100mm) reduce raw material waste by 2,500-4,000 tons/year—saving 10-16 million RMB annually (based on 4,000 RMB/ton steel price).
- Maintenance Cost Reduction by 20%-30%: 30% longer blade life and 40% lower electrical component failure rates cut annual maintenance costs by 500,000-800,000 RMB.
- Lower Post-Process Costs: Smooth shear surfaces reduce finishing workload (grinding, trimming), lowering labor and energy expenses.
5. End-to-End Service Support: Not Just “Selling Equipment” – But “Partnering for Lifecycle Success”
We understand that industrial equipment value extends beyond the product itself to installation, commissioning, and long-term support. That’s why we offer “full-lifecycle concierge service”:
- Pre-Sale Customization: Tailor solutions to your line layout, process needs, and material characteristics, providing 3D layouts and technical parameter sheets for perfect compatibility.
- In-Sale Support: Professional technicians on-site guide installation, commissioning, and operator training to ensure rapid production launch.
- After-Sale Guarantee: 18-month warranty with free repairs and wear part replacement. Dedicated service team available 24/7 for technical consulting, remote diagnostics for common issues, and on-site support within 48 hours for emergencies.
- Long-Term Partnership: Provide equipment upgrades, spare parts supply, and process optimization to align with your capacity expansion and technical advancements.
In today’s competitive steel rolling industry, “cost reduction and efficiency enhancement” are core competitive advantages. Our high-precision flying shear comprehensively addresses rolling line cutting pain points—from scenario adaptability and precision control to reliability, cost savings, and service—emerging as a true productivity engine that creates lasting value.
Whether upgrading aging equipment, equipping new lines, or optimizing existing processes, we deliver customized solutions. For detailed technical proposals, case studies, or quotations, feel free to send a private message. Let’s collaborate to make your rolling line more efficient, stable, and competitive!
