If you are looking for any kind of machine that runs on reels, then you will undoubtedly need a decoiler or decoiler.
Investing in capital equipment is an undertaking that requires you to consider many factors and features. Do you need a machine that meets your current production needs or are you looking to invest in next-generation capabilities? These are questions shop owners often ask themselves when purchasing a roll forming machine. However, little attention has been paid to research on unwinders.
If you are looking for any machine that runs on reels, then you will undoubtedly need a decoiler (or decoiler as it is sometimes called). Whether you have a roll forming, stamping or slitting line, you will need a web decoiler for the following process; There’s really no other way to do it. Ensuring your decoiler matches the needs of your shop and project is critical to keeping your roller mill running, as without material the machine will not be able to operate.
The industry has changed greatly over the past 30 years, but unwinders have always been designed to meet the specifications of the reel industry. Thirty years ago, the standard outside diameter (OD) of steel coils was 48 inches. As the machine became more customized and projects required different options, the steel coil was adjusted to 60 inches and then to 72 inches. Today, manufacturers sometimes use outside diameters (ODs) greater than 84 inches. exist. Coil. Therefore, the unwinder must be adjusted to accommodate the changing outer diameter of the reel.
Unwinders can be found throughout the roll forming industry. Today’s roll forming machines have more features and capabilities than their predecessors. For example, 30 years ago, roll forming machines operated at 50 feet per minute (FPM). They now operate at speeds of up to 500 feet per minute. This change in roll forming also expands the capabilities and base options of the decoiler. Simply choosing any standard unwinder is not enough; you also need to choose the right unwinder. There are many factors and features to consider to ensure your store’s needs are met.
Manufacturers of decoilers offer various options for optimizing the roll forming process. Today’s unwinders range in weight from 1,000 pounds. Over 60,000 lbs. When choosing an unwinder, consider the following characteristics:
You also need to consider what type of project you will be doing and what materials you will be using.
It all depends on the parts you want to use in your roller mill, including whether the roll is pre-painted, galvanized, or stainless steel. All of these characteristics will determine which unwinder features you need.
For example, standard decoilers are single-sided, but having a reversible decoiler can reduce wait times when loading material. With two mandrels, the operator can load a second roll into the machine, ready to process when needed. This is especially useful in situations where the operator has to change spools frequently.
Manufacturers often don’t realize how useful unwinders can be until they realize that, depending on the roll size, they can make six to eight or more changes per day. As long as the second roll is ready and waiting on the machine, there is no need to use a forklift or crane to load the roll once the first roll is used up. Unwinders play a critical role in coil forming processes, especially in high-volume production where a machine can form parts over an eight-hour shift.
When investing in a decoiler, it is important to understand your current features and capabilities. However, it is also important to consider the future use of the machine and possible future projects involving the roll forming machine. These are all factors that need to be considered accordingly and can really help you choose the right unwinder.
Coil carts help load coils onto mandrels without waiting for a crane or forklift to complete the operation.
Choosing a larger arbor size means you can use smaller spools on the machine. So, if you choose 24 inches. Spindle, you can run something smaller. If you want to jump 36 inches. option, then you need to invest in a larger unwinder. It is important to look for future opportunities.
As reels become larger and heavier, safety becomes a major concern on the shop floor. Unwinders have large, fast moving parts, so operators must be trained in the machine’s operation and proper settings.
Today, roll weights range from 33 to 250 kilograms per square inch, and unwinders have been modified to meet the yield strength requirements of the rolls. Heavier reels pose greater safety concerns, especially when cutting belts. The machine is equipped with pressure arms and buffer rollers to ensure that the web unwinds only when needed. The machine may also include a feed drive and a sideshift base to help center the roll for the next process.
As the spools become heavier, it becomes more difficult to unroll the mandrel by hand. Hydraulic expansion mandrels and rotation capabilities are often required as shops move operators from the unwinder to other areas of the shop for safety reasons. Shock absorbers can be added to minimize unwinder misrotation.
Depending on the process and speed, additional security features may be required. These features include outward-facing roll holders to prevent rolls from falling out, control systems for outside roll diameter and rotation speed, and unique braking systems such as water-cooled brakes for production lines operating at high speeds. This is important to ensure that when the roll forming process stops, the unwinder also stops.
If you are working with materials of different colors, special decoilers with five mandrels are available. This means you can fit five different rolls on the machine at the same time. Operators can produce hundreds of parts in one color and then switch to a second color without wasting time unloading spools and switching.
Another feature is the roll cart which helps in loading the roll onto the mandrel. This ensures that operators do not have to wait for a crane or forklift to load.
It is important to take the time to explore the different unwinder options. With adjustable mandrels to accommodate different inner diameter rolls and different sizes of roll support plates, there are many factors to consider to find the right fit. Listing current and potential features will help you determine the features you need.
Like any other machine, a molding machine is only profitable when it is running. Choosing the right decoiler to suit your shop’s current and future needs will help your roll forming machine operate more efficiently and safely.
Jasvinder Bhatti is vice president of application development at Samco Machinery, 351 Passmore Ave., Toronto, Ontario. M1V 3N8, 416-285-0619, www.samco-machinery.com.
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Post time: Jan-14-2024