Roller feeders are widely used in conjunction with punch presses, but operators often encounter the issue of material deviation. This problem, where the material fails to move in a straight line between the feeder and the die, can significantly impact the quality of stamped products and even damage the equipment. Addressing material deviation promptly is crucial to maintaining production efficiency. Here, we delve into the main causes of material deviation in roller feeders and provide actionable solutions.

Uneven Pressure from Top Pressing Springs

One common cause of material deviation is uneven pressure applied by the top pressing springs of the roller feeder. When the pressure on the two springs differs significantly, the material tends to move towards the side with the higher pressure, leading to deviation.

Solution:

  • Adjust Spring Pressure: Ensure that the pressing force on both springs is as equal as possible. This adjustment prevents the material from slipping or deviating during the feeding process. The pressing force should be balanced—neither too strong to damage the material nor too weak to cause slippage.

Incorrect Die Installation

Improper die installation can also lead to material deviation. If the roller feeder and the die are not aligned at a 90-degree angle, the material will not feed correctly. This misalignment often occurs when small dies are used on large tonnage punch presses, causing the dies to tilt.

Solution:

  • Realign the Die: Adjust the installation position of the die to ensure it is correctly aligned with the roller feeder. Proper alignment is crucial for preventing material deviation and ensuring smooth operation.

Material Issues

The condition of the material itself can cause deviation. Bent, uneven, or excessively burred materials do not move smoothly through the rollers of the feeder, leading to deviation.

Solution:

  • Use Qualified Material: Replace defective material with a qualified coil to ensure smooth feeding.
  • Add a Leveling Machine: If the material has significant bends or unevenness, installing a leveling machine in front of the feeder can help level the raw material and remove internal stress, preventing deviation.

Maintaining Optimal Roller Feeder Performance

Preventing material deviation is essential for the optimal performance of roller feeders and punch presses. By addressing the causes of deviation—whether it’s uneven spring pressure, incorrect die installation, or material defects—operators can maintain high-quality production and avoid equipment damage.

Regular maintenance and proper setup of the roller feeder and die can go a long way in ensuring smooth and efficient operation. By implementing these solutions, operators can effectively prevent material deviation, ensuring consistent production quality and prolonging the lifespan of their equipment.

Roller Feeder
Roller Feeder