In the intricate domain of stamping manufacturing, the process often begins with the unwinding of the material coil from the decoiler. The material then smoothly transitions into a leveler or feeder. However, the disparity in speed between the unwinding action of the decoiler and the feeding rate of the leveler can often present hurdles.

This bottleneck can be mitigated by equipping a basic decoiler with an inverter. The inclusion of an inverter provides manual control over the decoiler motor’s speed and stop-start function, aligning it better with the feeder’s speed. But, this solution necessitates frequent manual adjustments and repeatedly powering on and off the decoiler motor. This incessant operation could hasten the wear and tear of the motor and its electrical components and subsequently amplify energy consumption.

Bridging the Gap with Light-Control Sensing Technology

The natural question arising from this dilemma is: Is there an effective and dependable solution? The answer is a firm yes! The optimal resolution lies in implementing a light-control sensing device onto the inverter-equipped decoiler. By replacing the traditional sensor rod with this state-of-the-art light-control sensing apparatus, the decoiler can calibrate its unwinding speed in sync with the real-time material usage rate of the subsequent leveler or feeder, courtesy of the inverter. Consequently, the light-controlled decoiler no longer necessitates constant manual interventions or incessant stop-start sequences, thereby achieving automation, speed regulation, and stable unwinding.

Anatomy of the Light-Control Sensor Mechanism

The light-control sensor mechanism, an integral part of the decoiler, is composed of a photoelectric detection head and a corresponding receiver. Positioned at the leveler’s leading edge, the detection head releases light that the receiver, stationed at the material rack’s side, captures. Together, they form a safety light curtain, controlled by the inverter installed on the decoiler’s side.

The Working Principle of the Light-Controlled Decoiler

The operating mechanism of the light-controlled decoiler is quite ingenious. When the decoiler rotates too fast, the sagging degree of the coil increases, consequently blocking the light emitted by the photoelectric detection head. This action leaves the photoelectric receiver devoid of signals. On the contrary, if the decoiler’s rotation is sluggish, the coil’s sagging degree reduces, allowing the receiver to pick up light from the detection head. The photoelectric receiver subsequently communicates this signal to the inverter.

The inverter controller then modulates the power supply frequency to the rack motor, thereby adjusting the speed of the decoiler motor. The end result is a perfectly synchronized dance between the decoiler’s velocity and the leveler’s pace.

With the introduction of light-control sensing technology in stamping manufacturing, we’re witnessing the dawn of an era marked by improved efficiency, increased longevity of equipment, and substantial energy savings. This remarkable evolution, therefore, sets a new benchmark in the industry.