In the world of precision stamping, electronic hardware components often require a thin film to be applied to the surface of raw materials to protect them from damage. As the demand for high-quality material surfaces grows, it becomes increasingly important to find efficient ways to manage the collection of thin films and paper tapes during secondary stamping processes. Traditional stamping automation equipment often falls short in this regard, leading to operational inconveniences. To address this challenge, our company has developed a cutting-edge thin film and paper tape collection device, known as the “film collector.”
Seamless Integration and Installation
The film collector is designed to be installed right after the leveling machine, which ensures optimal material protection during leveling and simplifies installation. In situations where material leveling is not required, the film collector can be mounted on the decoiler machine. Regardless of the installation location—whether on the leveling or decoiler machine—the intermittent nature of stamping feed requires synchronization of the thin film (or paper tape) collection with the movement of the material strip. Failure to synchronize may lead to an ineffective film collector or even film elongation and breakage due to inconsistent speeds or continuous operation during machine stoppage.
Tackling Synchronization Challenges
To achieve synchronization, one potential solution involves employing tension control principles using torque motors to generate constant tension for proper handling of the thin film. Although theoretically ideal, torque motors often burn out in real-world production environments due to frequent start-stop cycles. Furthermore, operators may inadvertently leave the film collector running after shutting down the machine or ceasing operation, increasing the likelihood of torque motor burnout.
A Robust and Reliable Alternative
Given the operational risks associated with torque motors, our company sought to develop a design that minimizes adverse effects, even in cases of operational errors. After extensive research and discussion, we have introduced an innovative film collector that utilizes a standard motor for power and features a friction clutch mechanism on the transmission shaft. This design allows for easy adjustment of the pulling force exerted on the thin film.
Protecting Motors from Burnout
When the leveling or decoiler machine stops, the film collector continues to rotate, gradually increasing the pulling force on the thin film. Upon reaching a predetermined tension value, the friction clutch disengages, stopping the collection reel while the motor continues to run (idle), effectively preventing motor burnout due to excessive load. When the leveling or decoiler machine resumes operation, the thin film is released simultaneously, and the pulling force exerted by the film collector decreases. As the tension falls below the predetermined value, the friction clutch re-engages, and the motor resumes driving the collection reel.
Enhancing Efficiency and Dependability
Our refined film collector design effectively addresses the challenges and risks associated with torque motor-based solutions, providing a more reliable and practical alternative for managing thin film and paper tape collection in precision stamping processes. By incorporating a friction clutch mechanism, we ensure that even in the event of operational errors, the device will not produce detrimental consequences. This advanced solution ultimately enhances the overall efficiency and dependability of stamping operations, setting a new standard in the industry.