Stamping processing is a common production method in the manufacturing industry. Before the production process begins, the coil must undergo uncoiling. The most commonly used equipment for stamping production is the decoiler. However, standard decoilers often experience synchronization issues with the rear-leveling machine or feeder during operation, leading to reduced material feeding smoothness and increased vibration and deformation.
To address this issue, a frequency converter has been developed as a special accessory for the decoiler, which can automatically change the speed of the decoiler according to the running speed of the rear-leveling machine or feeder. By doing so, it can significantly reduce the number of start-stop cycles for the decoiler and improve the smoothness of uncoiling, while reducing material vibration and deformation, extending equipment lifespan, and significantly reducing power consumption. In this article, we’ll take a closer look at how this technology works and why it is becoming a commonly used optional device for the decoiler.
The Traditional Decoiler and Its Limitations
Before we dive into the details of the frequency converter, let’s first take a closer look at the traditional decoiler and the challenges it faces. The decoiler is a machine that uncoils metal coils for use in stamping production. It works by pulling the coil through a set of rollers that gradually unroll the metal sheet. However, the standard decoiler often experiences synchronization issues with the rear-leveling machine or feeder during operation. This means that the material feeding smoothness is reduced, and the material can vibrate and deform during operation. It also results in frequent motor starts for the decoiler, which significantly impacts the lifespan of the equipment and increases power consumption.
The Solution: The Frequency Converter
To address these issues, a frequency converter has been developed as a special accessory for the decoiler. When used with the decoiler, the frequency converter can automatically change the speed of the decoiler according to the running speed of the rear-leveling machine or feeder, rather than just controlling start-stop. This significantly reduces the number of start-stop cycles for the decoiler, while improving the smoothness of uncoiling and reducing material vibration and deformation.
How Does the Frequency Converter Work?
The decoiler equipped with the frequency converter achieves automatic speed control through a variety of components, including the induction pendulum rod, time relay, intermediate relay, potentiometer, electronic IC board, and frequency converter. As the decoiler speed changes, the sagging amplitude of the sheet metal also changes. The head of the induction pendulum rod moves up and down accordingly. When the rear-leveling machine or feeder runs at a high speed, the sagging amplitude of the sheet metal becomes smaller, and the head of the induction pendulum rod moves upward. Conversely, when the sagging amplitude of the sheet metal becomes larger, the head of the induction pendulum rod moves downward.
As the head of the induction pendulum rod moves up and down, the center point of the potentiometer moves, creating different resistance values. This change in resistance value enters the electronic IC board, undergoes internal calculation and processing, and outputs an analog signal to the motor frequency controller to adjust the speed of the decoiler. This ensures that the speed is consistent with that of the rear-leveling machine or feeder, achieving fully automated speed control.
Conclusion
In conclusion, the use of a frequency converter with the decoiler is an effective way to solve synchronization issues with the rear-leveling machine or feeder during stamping production. By automatically adjusting the speed of the decoiler, it reduces the number of start-stop cycles, improves the smoothness of uncoiling, and reduces material vibration and deformation. This leads to extended equipment lifespan and reduced power consumption, ultimately resulting in significant cost savings for your manufacturing operations.
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