In the realm of sheet metal processing, the conventional use of large-scale roller pressing equipment has been the norm for shaping metal sheets continuously. To boost production efficiency, streamline processes, and alleviate labor intensity, raw material sheets are pre-coiled into circular steel rolls and stored on specialized decoilers, maintaining optimal control and order. Decoiler machines, pivotal in this process, come in various forms, namely mechanical passive decoiler machines, semi-automatic decoiler machines, and fully automatic speed-controlled decoiler machines.
Evolution of Decoiler Machines: Types and Functions
1. Mechanical Passive Decoiler Machines
Traditionally non-powered, mechanical passive decoiler machines serve the basic function of unwinding cylindrical steel coils. Despite their simplicity, they lack the sophistication needed for modern, high-speed sheet metal processing.
2. Semi-Automatic Decoiler Machines
Controlled by an induction frame for start-stop functions, semi-automatic decoiler machines have been widely adopted in automated stamping production lines. However, their reliance on induction frames results in a lack of precise real-time control over material feed speed, leading to issues like excessive sagging and compromised quality.
3. Fully Automatic Speed-Controlled Decoiler Machines
Innovating beyond traditional methods, our professionals have developed fully automatic speed-controlled decoiler machines. Departing from induction frame control, these machines utilize a frequency converter and three sets of switches. Photocells connected to the frequency converter detect the degree of sagging in the sheet, enabling real-time adjustments in the reduction motor’s speed. This groundbreaking approach ensures precise control over production speed, addressing challenges related to loose winding, pulling straight, and enhancing overall decoiler lifespan.
Unraveling the Mechanism: Real-Time Control for Precision Uncoiling
The fully automatic speed-controlled decoiler machine operates seamlessly to facilitate the unwinding of coils in practical applications. The reduction motor drives the rotating shaft, allowing the uncoiled sheet to gently sag over photocell switches before entering the sheet metal processing production line. Real-time control is achieved through the interaction of photocells, the frequency converter, and the reduction motor.
– Photocell Switches and Frequency Converter Interaction
- Sag Detection: Photocells detect the sagging degree of the uncoiled sheet.
- Control Signal Emission: Upon detection, photocells emit a control signal to the frequency converter.
- Speed Adjustment: The frequency converter, in response, adjusts the reduction motor’s speed, ensuring a smooth start and stop of the decoiler machine.
– Responding to Processing Speed Changes
- Increased Speed: If the processing speed of the main machine in the production line accelerates, causing reduced sagging over photocell switches, a control signal is sent to increase the reduction motor’s speed.
- Decreased Speed: Conversely, a slowdown in processing speed increases the sagging degree. In this scenario, the frequency converter decreases the reduction motor’s speed.
– Addressing Abnormal Sagging
In cases where the sagging degree falls significantly below normal levels, causing blockage of the light for the third group of photocells, the frequency converter triggers the reduction motor to reverse the rotation of the rotating shaft, retracting the excess sheet.
Conclusion: Transforming Sheet Metal Processing Efficiency
The fully automatic speed-controlled decoiler machine stands as a transformative innovation in sheet metal processing. With its ability to provide real-time control over material feed speed, it mitigates issues like sagging, loose winding, and straight pulling, contributing to higher-quality outcomes and prolonged decoiler lifespan. Embrace this evolution to revolutionize your sheet metal processing endeavors.