Decoilers: A Necessity for Automated Manufacturing
In the domain of stamping and shearing production, the crucial requirement for achieving automated manufacturing lies in the use of coil material. The decoiler, as a dedicated apparatus for handling coiled materials, plays a pivotal role in this context. Among the various categories of decoilers, the heavyweight decoiler is particularly celebrated for its remarkable adaptability to material thickness and width, as well as its capacity for customized configurations. It has risen to become the preeminent material unwinding device.
The Working Mechanism of Conventional Decoilers
Traditional decoilers operate based on inductive sensing. As they unroll and feed the coiled metal into the subsequent leveling machine, the inherent gravitational forces acting on the material cause it to sag during the transfer. This sag, positioned between the decoiler and the leveling machine, creates a curvature due to gravity. When this curvature encounters the inductive sensing frame, it triggers the decoiler to pause its operation. Once the sag is no longer detected, the decoiler automatically resumes operation, allowing for complete automation.
Challenges of Conventional Decoilers
However, conventional decoilers have inherent limitations that cannot be ignored. Firstly, they require the material to be metallic. Secondly, the speed at which the decoiler unrolls the material affects the height of the sag, leading to issues like slackening or over-tightening. A high unrolling speed elevates the sag height, causing slackening, while a slower speed reduces the sag height, causing over-tightening and coiling. These issues can result in material stretching, deformation, and damage, potentially affecting both the leveling machine and the decoiler.
A Revolutionary Solution: The Light-Controlled Decoiler
To address the drawbacks of conventional decoilers, a cutting-edge solution has been developed: the light-controlled decoiler. This innovative approach replaces inductive sensing with multiple sets of photoelectric switches for precise control. These switches monitor the sag height, adjusting the decoiler’s shaft rotation speed with remarkable accuracy. This breakthrough eliminates the issues of coiling and slackening, ultimately enhancing stamping production efficiency.
Integration into Modern Production Systems
The light-controlled decoiler has become an integral part of three-in-one feeders, featuring three sets of vertically aligned opposed photoelectric components. These components interface with the decoiler’s inverter in the electrical enclosure to regulate speed. When the first set of photoelectric components detects material, it signals that the unwinding speed is too slow. The controller prompts the decoiler to accelerate, preventing coiling and potential damage. Conversely, when the second set of components detects material, it indicates excessive unwinding speed, and the inverter instructs the decoiler to slow down, avoiding slackening. The third set of components, when activated, offers comprehensive control over the decoiler, achieving precise automation.
Conclusion: Advancing Stamping and Shearing Production
In conclusion, the light-controlled decoiler represents a significant advancement in the realm of stamping and shearing production. By replacing traditional inductive sensing with photoelectric switches, it overcomes the limitations of the standard decoiler and significantly improves production efficiency. As we continue to innovate and refine these technologies, the future of automated manufacturing looks brighter than ever.