Device and method for leveling a metal plate

A method for leveling a metal material having opposing surfaces, comprising:

• providing a serpentine path in a longitudinal direction between a single upper roller and a corresponding single pair of lower rollers that are rotatably disposed in a parallel arrangement in a lateral direction, such that the longitudinal direction is associated with a direction of travel for the metal material;
• wherein the single upper roller includes an upper roller radius and an outer peripheral surface that define a bottom-dead-center point that is positioned below a passline, and each of the single pair of lower rollers includes a lower roller radius and an outer peripheral surface that define a top-dead-center point;
• wherein the serpentine path and the upper and lower rollers are disposed to accommodate the metal material;
• wherein the single pair of lower rollers includes:
• a first lower roller positioned such that the top-dead-center point thereof is disposed at the passline;
• and
• a second lower roller positioned such that the top-dead-center point thereof is above the passline;
• wherein providing the serpentine path includes:
• positioning the single upper roller in between the first lower roller and the second lower roller in the longitudinal direction such that a first longitudinal spacing is defined between the axis of rotation of the first lower roller and the single upper roller and a second longitudinal spacing is defined between the axis of rotation of the single upper roller and the second lower roller;
• positioning the first lower roller relative to the single upper roller in an elevation direction, such that a first plunge depth is defined as a difference in the elevation direction between a first lower elevation associated with the top-dead-center point of the first lower roller and an upper elevation associated with the bottom-dead-center point of the single upper roller;
• and
• positioning the second lower roller relative to the single upper roller in the elevation direction, such that a second plunge depth is defined as a difference in the elevation direction between a second elevation associated with the top-dead-center point of the second lower roller and the upper elevation associated with the bottom-dead-center of the single upper roller;
• wherein the magnitude of the first plunge depth is less than the magnitude of the second plunge depth such that the first lower roller and the single upper roller impart a first bend radius on the metal material in a first orientation and the single upper roller and the second lower roller impart a second bend radius on the metal material in a second orientation that is opposite the first orientation when the metal material moves through the serpentine path to provide equal plastification on both sides of the metal material;
• and
• wherein a magnitude of plastification of the metal material is sufficient to level the metal material;
• wherein the magnitude of the first bend radius is less than the magnitude of the second bend radius;
• and
• wherein there is a quantity of not more than the single upper roller and a quantity of not more than the single pair of lower rollers to achieve equal plastification on both sides of the metal material.