In the dynamic world of sheet metal shearing, the velocity of the shearing machine stands as the linchpin in the operational rhythm of the entire production line. Achieving seamless synchronization between the unwinding speed of the decoiler and the shearing machine is pivotal. However, a challenge arises: as the shearing machine maintains a constant speed, the material coil on the decoiler steadily diminishes. This prompts an inevitable rise in the rotational speed of the material stand, where the material is dispensed. Traditionally, a manual approach involves monitoring material height in the feeding pit and manually adjusting the decoiler speed. While effective at slower speeds, this method leads to delayed reactions, causing issues such as material dragging or tension at higher and lower unwinding speeds, respectively. In an era of fierce competition where efficiency is paramount and human intervention must be minimized, this antiquated manual speed-matching process falls short.

The Evolution: From Manual Adjustments to Precision Automation

To address the challenge of imprecise synchronization between the decoiler and shearing machine speeds, we’ve transitioned from the traditional induction bracket control to a state-of-the-art system employing a triad of photoelectric controls. This transformative modification not only automates speed matching but also significantly enhances production efficiency while minimizing wastage. In contrast to the traditional manual approach, this method ensures superior precision and reliability in the shearing process.

Unveiling the Automated Shearing Production Line with Photoelectric Controls

The operational principle of an automated shearing production line equipped with a photoelectric-controlled decoiler is a paradigm shift in efficiency. In this innovative system:

1. Real-Time Material Height Monitoring

Three sets of strategically positioned photoelectric switches on the inner wall of the feeding pit continually monitor the material’s height in real time. This eliminates the need for manual observation and ensures instantaneous responsiveness to changes in material height.

2. Digital Precision with D/A Conversion Circuit

A digital-to-analog (D/A) conversion circuit plays a crucial role in the automation process. It transforms the digital signal of the shearing motor speed feedback into an analog signal. This analog signal is then transmitted through the three sets of photoelectric switch sensors to the adder, ensuring precision and accuracy in the speed-matching process.

3. Automated Speed Matching in Action

As the material height in the feeding pit fluctuates, the photoelectric switches respond accordingly. When the material height falls below a certain level, the switch remains connected; when it surpasses the set level, the switch disengages. The adder, utilizing the signals from the photoelectric switches through the D/A conversion circuit, automatically calculates the optimal setpoint signal. This signal is then fed back to the material stand motor controller. Subsequently, the material stand motor controller, adjusting the rotational speed of the material stand motor, seamlessly mirrors the shearing machine’s speed. This automated speed matching ensures a harmonious production flow, significantly boosting overall efficiency.

The Future of Shearing: Fully Automated Speed Control

In conclusion, the shift from manual observation to automated speed control in sheet metal shearing is a game-changer. By embracing photoelectric controls, we’ve not only overcome the limitations of traditional methods but also ushered in an era of precision and efficiency. The fully automated speed control system ensures that the decoiler and shearing machine work in perfect tandem, minimizing human intervention and maximizing production output. In the competitive landscape of shearing production, this innovation is not just an upgrade; it’s a revolution.

 

Sheet Metal Shearing
Sheet Metal Shearing