How does an uncoiler work?

Introduction of Uncoiler and Its Functions and Features

View Details

-12-29

Uncoiler is special equipment for sheet metal leveling. It is applied to the leveling line of steel plates and uneven plates, which can form uncoiling, leveling, shearing production lines, and other plate product production lines according to related configurations. The uncoiling machine is suitable for industries such as machinery, vehicles, metal products, household appliances, steel structures, and decoration.

Uncoiler machine is one of the essential equipment in the welded pipe production line. On the one hand, its function is to support the steel coil by tightening the inner hole of the steel coil; on the other hand, it is to feed the head of the steel strip into the leveling machine through the rotation with the cooperation of the straightening machine. Therefore, the performance of the uncoiling machine is very important to the entire production line. In many years of design practice, we have continuously optimized and improved the structure of the uncoiling machine, which has improved the performance of the uncoiling machine.

The main shaft of the uncoiler has two functions, namely, to drive the steel coil to rotate and to support tension of the steel coil. The realization of tightening is usually done by pushing the inclined slider by the oil cylinder or air cylinder installed with the main shaft. Small units use multiple cylinders, and large units use multiple cylinders; the realization of rotation is usually accomplished by the motor driving the main shaft to rotate through a reducer. The oil cylinder or air cylinder installed on the main shaft must rotate together with the main shaft, and the oil cylinder or air cylinder needs to be connected to one end of the working medium pipeline, and the other end of the pipeline is connected to the hydraulic station or solenoid valve.

One of the functions of the uncoiling machine of the unit is to unwind the strip under the tension after maintaining the strip. Another significant function is to realize the automatic centering of the strip under the central control (CPC). The conventional continuous rewinding and color coating unit is equipped with 2 uncoilers. Two uncoilers working alternately creates a prerequisite for the continuous production of the subsequent equipment of the unit.

The uncoiling machine is a welded box-shaped structure, and the variable frequency speed-regulating motor drives the drum shaft to provide the main power for the uncoiling machine after decelerating through the gearbox. The reel of the uncoiling machine is a hollow shaft, which is supported on the gearbox body through two bearings, and a transmission spur gear is installed between the bearings. The gearbox is lubricated by forced lubrication and is equipped with two constant speed motors for the closed-loop oil lubrication system. The mandrel is a cantilever structure, and its front end is supported by an external support bearing during unwinding to maintain the rigidity and stability of the uncoiling machine.

The mandrel of the uncoiling machine is connected to four sector-shaped plates through four sloped dovetail grooves on the end faces. Each sector-shaped plate is prevented from moving in the axial direction through a radial slide at the end but can expand and contract in the radial direction. A rotating oil cylinder is connected to the tail end of the reel shaft, and the piston rod of the oil cylinder drives the front-end quadrangular shaft to slide axially through a pull rod in the center of the reel shaft, thereby driving the sector plate to expand and contract radially. The nominal diameter of the reel can be increased by adding four fan-shaped plates. The frame of the uncoiler can be moved on the guide rail of the uncoiling machine base and driven by a hydraulic cylinder, which can realize the center position control. In order to strengthen the stability of the reel, a support arm device is designed on the head of the reel. When there is a steel coil on the reel, the support arm is driven by the cylinder to support the head of the reel, the support arm usually retracts, and it will not affect the coiling of the steel coil.

Investing in capital equipment is an undertaking that requires you to consider many factors and features. Do you need a machine that meets current manufacturing needs, or do you want to invest in next-generation features? These are questions shop owners ask themselves all the time when purchasing a roll former. However, far less attention is given to investigating the uncoiler.

If you are looking for any machine that will run using coils, you no doubt need an uncoiler (or decoiler, as it is sometimes referred to). Whether you have roll forming, stamping, or slitting lines, an uncoiler is required to unroll the coil for the next process; there really is no other way to do it. Ensuring that the uncoiler meets your shop and project needs is essential in keeping the roll former forming, because without the material the machine cannot operate.

The industry has changed a lot over the past 30 years, but uncoilers have always been designed based on specifications from the steel coil industry. Thirty years ago steel coils had a standard outer diameter (OD) of 48 in. As machines became more customized and projects required different options, coils were adapted to 60 in. and then to 72 in. And today fabricators occasionally use upwards of 84-in. coils. So uncoilers have had to be adapted to fit the changing coil ODs.

Uncoilers are used everywhere in the roll forming industry. Today&#;s roll formers have more features and capabilities than their predecessors had. For example, 30 years ago a roll former could operate at 50 ft. per minute (FPM). Now they can run up to 500 FPM. This change in roll forming production has also increased capabilities and the base range of uncoiler options. It&#;s not enough to just pick any standard uncoiler; a lot of factors and features need to be considered to ensure that shop needs are met.

With competitive price and timely delivery, Lihao Machine sincerely hope to be your supplier and partner.

Choosing the Right Uncoiler

Uncoiler manufacturers offer a variety of options to ensure roll forming processes can be optimized. Today&#;s uncoilers range from 1,000 lbs. to more than 60,000 lbs. When choosing an uncoiler, keep these specifications in mind:

• Weight of coil
• ID and OD of coil
• Width of coil
• Coil thickness (min. and max.)
• Number of coils being loaded
• Speed of roll former and coil changeover time
• Footprint
• Budget
• Application/next process

You also need to consider what type of projects you will be taking on and the material you will be using.

It all depends on what you&#;re going to be running on the roll former, including whether the coil is prepainted, galvanized, or stainless steel. These specifications will all determine what uncoiler features you will need.

For example, standard uncoilers are singleended, but having a double-ended uncoiler can reduce material handling wait times. Having two mandrels allows the operator to load a second coil on the machine, ready to be processed when needed. This is especially helpful in situations where operators are constantly having to change over coils.

Fabricators often don&#;t realize how useful an uncoiler is until they realize that, depending on the size of the coil, they can have changeovers six to eight times or more per day. Having a second coil ready and waiting on the machine eliminates the immediate need for a forklift or crane to load a coil once the first one is out of material. An uncoiler performs a critical function in roll forming environments, especially in large-run operations where the machine may be forming parts across an eight-hour shift.

Knowing your current specifications and capabilities is important when investing in an uncoiler. However, it&#;s also important to think about the future use of the machine and what possible future projects will be on the roll former. These are all factors that need to be considered accordingly and really help to determine the proper uncoiler.

Opting for a larger mandrel means that you can run a smaller coil on the machine. So, if you opt for a 24-in. mandrel, you can run anything less than this. If you want to jump to a 36-in. option, then you need to invest in a larger uncoiler. It&#;s important to look to future opportunities.

Safety Features

Safety is a major concern on the shop floor as coils have become larger and heavier. Uncoilers have large, fast-moving parts, so operators must be trained on how the machine works as well as its correct setup.

Coils today can range from 33 to 250 kilopounds per square inch, and the uncoiler has been adapted to meet the demands in the yield strength of the coil. Heavier coils present bigger safety challenges especially when cutting the strap. Hold-down arms and snubber rolls are included on the machine to ensure the coil unwinds only on demand. The machine also can include feed-up drives and a side shift base to help centre the coil for the next process.

As coils get heavier, it becomes much harder to expand the mandrel manually. Hydraulic expanded mandrels and rotation capabilities are commonly requested as shops move operators away from the uncoiler for safety reasons and into other areas of the shop floor. Shock absorbers can be added to minimize uncoiler rotational abuse.

Depending on the process and speed, additional safety features might be required. These features include an outward coil retainer to prevent the coil from falling down, a monitoring system for the OD and RPM of the coil, and a unique braking system like water-cooled brakes for lines running at high speeds. These are all important to help ensure that when the roll forming process stops, the uncoiler also stops.

Special Options

If you take on a job using multiple coloured materials, special uncoilers are available that offer five mandrels, meaning you can have five different coils resting on the machine at a time. The operator can make a few hundred pieces of one colour and then switch to a second colour without spending time unloading the coil and switching it over.

Another feature is a coil car, which helps to load the coil onto the mandrel. This ensures the operator doesn&#;t need to wait for a crane or a forklift to load it.

It&#;s important to take the time to investigate the different options available for the uncoiler. With adjustable mandrels to accommodate coils with varying inside diameters, and several size options for the coil back plate, you have many factors to consider to find the right fit. Making a list of current and potential specifications will help you to determine the necessary features.

A roll former, like any other machine, is making money only when it&#;s operating. Choosing the right uncoiler for you shop&#;s current and future needs will help your roll former operate more efficiently and safely.

Jaswinder Bhatti is vice-president of applications engineering for Samco Machinery, 351 Passmore Ave., Toronto, Ont. M1V 3N8, 416-285-, www.samco-machinery.com.

For more Uncoilers, Metal Sheet Uncoiling Machineinformation, please contact us. We will provide professional answers.