In the realm of coil material processing, the efficiency of a decoiler hinges on seamless coordination during the unwinding process. The conventional decoiler operates by unwinding the coil material on a supporting tile plate, necessitating synchronization with subsequent leveling and feeding machines. Let’s delve into the intricacies and innovations, with a focus on optimizing performance and safety.

Synchronizing Unwinding with Leveling and Feeding Machines

In the conventional setup, intermittent feeding is regulated by an inductive rod as the coiled material gradually unwinds. Ensuring the stationary state of the supporting tile plate when the decoiler halts is crucial. To achieve this, a belt-driven gearbox with substantial gear reduction is employed, inducing braking on the supporting tile plate. This prevents the release of excessive coiled material, averting potential bending and damage to the material surface.

Overcoming Challenges with Heavy Coil Loads

Practical decoiler usage reveals a challenge when the coiled material becomes excessively heavy. The inertia generated during the rotation of the coil puts significant strain on the motor, impacting the longevity of the decoiler. After motor cessation, the belt’s continued operation can potentially damage the gearbox, leading to severe consequences, such as fracturing a corner of the gearbox. This not only diminishes the decoiler’s lifespan but also poses safety risks to stamping production.

Enhancing Reliability: Pneumatic Disc Brake Devices

In response to these challenges, our manufactured decoilers, especially those designed for heavier coil loads exceeding 3 tons, come equipped with pneumatic disc brake devices. Let’s explore the key components and functionalities of this innovative braking system.

Components of the Pneumatic Disc Brake Device

The pneumatic disc brake device comprises three main parts: the brake actuation device, clamping device, and fixture. The core component, the brake actuation device, features a hollow cylinder body with a diaphragm inside, along with a push rod, return rod, spring, and anchoring rod.

Functionality of the Brake Actuation Device

When coupled with the clamping device on the decoiler, the brake actuation device utilizes compressed air to initiate braking. The diaphragm resists the spring force, causing the return rod to move backward. This, in turn, disengages the push rod from the clamping device, releasing the clamping force on the fixture.

Conversely, upon air pressure release, the spring propels the return rod forward, forcing the push rod to engage the clamping device, activating the brake effect on the fixture. This ensures stable and proper brake operation under normal conditions.

Customizable Brake Force Adjustment

Fine-tuning the braking system is achieved by adjusting the forward movement of the push rod. This is done by moving the anchoring rod forward or backward through the rotation of a nut. The adjustment alters the spring’s elongation or compression, thereby changing the clamping force on the fixture and, consequently, the braking force magnitude.

Specialized Design for Enhanced Reliability

The distinctive advantage of the decoiler’s pneumatic disc brake system lies in the specialized design of the brake actuation device. Unlike conventional cylinder-based systems, this design allows seamless execution of the clamping function even in the event of external air supply failures. This eliminates the need for maintaining air pressure, ensuring a more reliable and secure user experience.

In conclusion, the incorporation of pneumatic disc brake devices in decoilers not only addresses operational challenges but also enhances reliability, providing manufacturers with a robust and efficient solution for processing heavier coil loads.