Heavy-duty decoilers play a critical role in the automation of production lines, ensuring the smooth and continuous operation of material processing. However, when the sensing function in these machines falters, it can have a significant impact on the overall efficiency of the production line. In this article, we will explore the common causes of sensing function issues in heavy-duty decoilers and provide practical solutions to address them.

Understanding the Causes of Sensing Function Cessation in Heavy-Duty Decoilers

  1. Inappropriate Time Relay Delay SettingsHeavy-duty decoilers rely on time relays, housed within their electrical boxes, to synchronize their operation with that of correcting or feeding machines. If the time relay delay is set too long, it can impede the decoiler’s normal operation.Solution: Adjust the time relay delay to a shorter setting or customize it to match the operational speed of the subsequent correcting or feeding machine.
  2. Loose or Poorly Connected Sensing Rod WiringDuring the operation of heavy-duty decoilers, operators may need to adjust the sensing rod or frame to control the length of discharged material. This movement can sometimes cause the sensing connection wire to loosen, leading to a loss of signal transmission.Solution: Regularly inspect the sensing circuit connections and ensure proper connection of all wires.
  3. Damaged Electrical Components within the Decoiler’s Electrical BoxIf any of the electrical components inside the decoiler’s electrical box – such as AC contactors, transformers, time relays, or intermediate relays – are damaged, the sensing function may be compromised.Solution: Perform a thorough inspection of all electrical components and replace any that show signs of damage.
  4. Decoiler Motor Drive Belt Issues or Disconnected Motor-Reducer PinFrequent relocation or transportation of the decoiler may cause the motor’s drive belt to slip off or the pin connecting the motor and reducer to become dislodged, hindering proper transmission.Solution: Inspect the belt connection and motor-reducer connection for any issues and make necessary adjustments.
  5. Non-Conductive Coil Material ReplacementIf customers replace the coil material with a non-conductive surface film or material, the decoiler’s sensing function may not operate as intended.Solution: Switch the sensing method of the heavy-duty decoiler to a microswitch or photoelectric switch. Be mindful of the material used and communicate with the equipment supplier regarding technical specifications.
  6. Damaged Decoiler MotorWhile the likelihood of motor damage is low, it can render the entire decoiler inoperable if it occurs.Solution: Contact the equipment supplier for a motor replacement under warranty.


Maintaining the sensing function of heavy-duty decoilers is crucial for ensuring optimal performance and productivity on automated production lines. By understanding the causes of sensing function issues and implementing the solutions outlined in this article, operators can effectively troubleshoot and resolve any problems that may arise, enhancing the overall efficiency of their production processes.