In the realm of heavy-duty stamping production lines, the hydraulic decoiler plays a pivotal role, positioned parallel to the centerline of the press, leveling machine, and feeder. This essential component not only bears the coil material but also executes the critical uncoiling operation while regulating tension during the unwinding process. Let’s delve into the intricacies of this process and explore recent innovations that address common challenges.
Optimizing Traditional Hydraulic Decoilers
The Conventional Set-up
Traditionally, hydraulic decoilers formed a robust connection between the main body and external hydraulic pipelines through a rotary joint. This joint, rigidly linked to the hydraulic expansion and contraction hydraulic cylinder at the spindle’s tail end, utilized seamless steel pipes with a diameter of 42*4 to connect hydraulic oil pipes to external pipelines.
Challenges in Stamping Production
In the course of stamping production, the hydraulic decoiler generates tension within the 19-35 kN range. This tension, unfortunately, induces tilting in the upper part of the rack frame, leading to eccentric swinging of the spindle and rotary joint. This movement, in turn, results in the compression and failure of the skeleton oil seal lip, causing leaks. The internal oil leakage, if not promptly addressed, exacerbates external leakage, significantly impeding effective stamping production.
Innovative Solutions: Revolutionizing the Rotary Joint
Overcoming Oil Leakage Challenges
To combat the frequent issue of oil leakage in traditional hydraulic decoilers, recent improvements have focused on the rotary joint of the rack. The pivotal change involves the synchronous swinging of the bushing used in the rotary joint with the main spindle of the rack. This adaptive design accommodates various working conditions of the rack, effectively addressing challenges encountered during stamping production.
Precision and Efficiency
The modified hydraulic decoiler’s rotary joint now integrates two-layer steel wire high-pressure rubber hoses, boasting a diameter of 38 mm and a length of 1500 mm, for connecting to the external hydraulic pipeline. The connection point strategically located near the straight section of the rotary joint ensures that it doesn’t interfere with the hydraulic decoiler’s sliding rail movement and spindle rotation. Maintaining a precise clearance between the rotary joint pivot and the bushing within the range of 0.04-0.06 mm ensures the synchronous swinging of the rotary joint bushing with the hydraulic decoiler.
Intelligent Design for Fluid Dynamics
An essential upgrade involves replacing the original 5mm oil drain hole in the rotary joint bushing with two evenly distributed 7mm holes in the circumferential direction. This thoughtful modification reduces the pressure of internal oil leakage, facilitating its timely discharge and, consequently, eliminating external leakage incidents.
Seal of Quality
The skeleton oil seal has also undergone a significant improvement, now employing a high-quality seal that tightly combines with the skeleton. This enhancement provides smoothness and superior rubber flexibility, offering a fundamental solution that drastically reduces hydraulic decoiler failures and subsequent maintenance costs.
In conclusion, the evolution of hydraulic decoilers, particularly in addressing oil leakage challenges through innovative rotary joint enhancements, marks a significant stride in optimizing stamping production efficiency. These upgrades not only ensure the smooth operation of hydraulic decoilers but also contribute to a substantial reduction in maintenance costs, making them a valuable investment for heavy-duty stamping processes.