Automated production lines have revolutionized the metal stamping and manufacturing industry, enabling more efficient production processes. Coiled and packaged materials are a vital component of these automated production lines, but they must be unwound and uncoiled before they can be used.
The Importance of Decoiler Machines
While lightweight materials or flat electronic feeders may be suitable for some applications, they are not feasible for heavy-duty materials that can weigh up to 2-3 tons. In these cases, a decoiler machine is the preferred choice. Decoiler machines utilize a vertical unwinding and uncoiling method, and they are crucial to achieving efficient production processes.
How Decoiler Machines Work
The coiled material is placed on a tensioning and expanding drum, which is then driven by a motor and reducer to rotate. The contact friction force between the tensioning and expanding drum and the coiled material is used to drive the coiled material to rotate and achieve the goal of decoiling. During the initial stages of production, the machine is operated in a jog mode for a short period of time to release a certain length of material. The released material is then manually pulled through various processing equipment such as a flattening machine, a feeder, or a punch press.
Automated Production with Decoiler Machines
Once this is done, the decoiler machine can be turned on and controlled automatically by an inductive frame to achieve fully automated production. This enables faster production processes and reduces the risk of human error, ensuring consistent output quality.
Challenges with Non-Conductive Materials
Non-conductive materials, such as silicon steel sheets, film materials, and some non-metallic materials, pose a unique challenge for decoiler machines. If an inductive frame is used to control the machine during production, the middle relay and time relay in the decoiler machine’s electrical box will not switch even if in contact with the non-conductive materials. This makes it impossible to control the stopping of the decoiler machine, which will continue to feed material without stopping and fail to achieve automated decoiling.
Opto-Electrical Decoiler Machines
To address this challenge, an opto-electrical decoiler machine is needed. An opto-electrical decoiler machine replaces the traditional contact inductive frame control method with a through-beam photoelectric switch. When the material decoils and droops to a certain extent, blocking the light, the machine will automatically stop. Once the material is raised, the machine will automatically start feeding again. The control is sensitive and does not require contact with the material, eliminating the problem of material scratching, and fundamentally realizing automated decoiling of non-conductive materials.
In conclusion, the decoiler machine is a key component of automated production lines in the metal stamping and manufacturing industry. With its ability to handle heavy-duty materials and perform vertical unwinding and uncoiling, it enables efficient production processes. The development of opto-electrical decoiler machines has expanded the capabilities of decoiler machines to handle non-conductive materials, further improving the efficiency and effectiveness of automated production lines.