Focus on coil processing
the press feed line, could not meet the part
quality requirements. To replace the flat-
tener/straightener and integrate a precision
leveler into the existing line required a cus-
tom hold-down peeler-threader and a cus-
tom-consolidated control package including
push-button controlled thread-up.
B&K’s engineering department was able to
design a control that would not only run the
precision corrective leveler but also control
the existing equipment in the press feed
line.
“Our ability to maintain 98% of our prod-
uct production within our facility allows
us full control over our shop throughput,”
explained Matt Watson. “Our 85,000ft
2

facility is designed to allow product to flow
and any foreign matter on the works rolls
Above: B&K
from raw material, at the fabrication end of
quickly transfers to the end product resulting
84-inch
the building, to finished product shipping to
leveler for
in excess scrap material being produced.
our customers from the assembly end of the
Tier One
“Downtime to clean the rolls and scrap
automotive
building. In the centre of our building, prod-
material are very costly for a user, so we
manufacture
uct flows through a machine shop which uses
incorporated a powered high-rise head
multiple horizontal turning centres and mul-
design into every leveler,” explained Matt
tiple CNC machining centres. A CNC bridge
Watson, B&K national sales and marketing
mill with travel capacity of 69”x x 126”y x
manager. “This feature allows the head of the
53”z is also critical to our operation.”
leveler to open with a push of a button and
B&K’s facility in the US also has roll harden-
provides 6” of clearance for quick and easy
ing and grinding capabilities. Programming
access to clean the rolls.”
for the machine shop is done with Surf cam
A new control platform was designed
software. Its manufacturing department is
to allow all the settings in the leveler to
staffed with seventy-one employees, it has an
be accomplished through the HMI (touch-
engineering staff of seven people, ten sales
screen) interface. The HMI (Human Machine
staff and seven people in the service depart-
Interface) also provides other operator ben-
ment. It offers a 24/7 service programme,
efits. A complete maintenance manual is
allowing customers direct contact with a
provided as well as an operator thread-up
factory technician at any time.
training manual and a complete diagnostics
package has been developed. A help screen
has been integrated to allow the operator a
reference setting based on incoming material
surface conditions (see the bottom of page
XX).
Leveler retrofi t installation
The B&K 84” wide 1.75” roll diameter leve-
ler was integrated into an existing press feed
line for a Tier One manufacturer of automo-
tive components. The spread-centered flat-
Above: The B&K 85,000-square foot manufacturing facility
tener/straightener, that was originally sold in in Clinton, Maine (USA)
50 March/April 2007 International Sheet Metal Review
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