The traditional stamping production line, an interplay of decoiler, leveler, and feeder, marks a staple in the industry. Each component in this chain, acting as an independent unit, carries out its distinct role. This kind of setup, while functional, demands individual oversight during setup and operation. To ensure steady performance during medium and thick sheet processing, material frames and levelers are paired with inverters. However, the need for considerable space between machines for stock handling, along with the intricate setup, operation, and lackluster synchronization between decoiling, leveling, and feeding, contributes to inconsistent feed repeatability. This inconsistency persists even when an NC servo feeder is employed, revealing a gap in the quest for smart, efficient, precise, and simplistic automated manufacturing.
Embracing the Three-In-One Press Feed Line
In the face of these limitations within the traditional stamping production line, contemporary medium and thick sheet processing is progressively pivoting to the use of short-process stamping production lines. The focus now is on the three-in-one press feed lines. By unifying decoiling, leveling, and feeding operations into a single piece of equipment, it fundamentally tackles the issues of coordination and stability. Furthermore, it introduces a unified control system, enabling all actions from a singular control panel. The ease of setup and operation, coupled with high automation levels, transforms the entire process – loading, decoiling, feeding, leveling, and feed – into a fully automated mechanism. Even an operator without formal training can efficiently manage the process. The three-in-one press feed line, in comparison to its traditional counterpart, offers a production efficiency increase of over ten times, promising lower production costs and higher output. The enhanced leveling and feed repeatability solidly boost the market competitiveness of those in the stamping business.
Revolutionizing Operations: The Role of the PLC System in the Three-In-One Press Feed Line
In the practical application of the three-in-one press feed line, the operation leans heavily on the control commands provided by the operators to the PLC system. This system, typically equipped with a high-precision Mitsubishi PLC, takes these commands and puts them into action. Firstly, it powers up the hydraulic station of the material rack section to give hydraulic power for loading. Once the material rack is ready, the rack inverter sets the decoiling motor into motion, which, linked to the main shaft of the decoiler, rotates to intelligently and automatically unload the material. Then, the PLC control module propels the feeding servo motor (standardly fitted with a Japanese Yaskawa servo motor) as per the parameter command. This ensures the leveling and calibration operations of the feed leveling platform are accurate, bringing about the automated operation of decoiling, leveling, and servo feeding.
Embracing the three-in-one press feed line, stamping business owners are not only equipping themselves with the tools to enhance efficiency and output, but they are also making strides in aligning with the direction of the industry – towards more intelligent, efficient, and precise manufacturing.