Plc Hydraulic Cold Roll Steel Forming Machine 3 In 1 Nc Servo Feeder

 

 

Model TNCF5 of Compact 3 In 1 NC Servo feeder Machine

 

 

Descrition:

 

I.  the layout of system

 

 

II. General Induction of press feed line

The Compact Coil Line principle revolves around combining the three functions of coil line, flattening and feeding of the material. This is typically achieved utilizing several configurations, a straightener/feeder unit along with a motorized uncoiler; a straightener/feeder unit along with a powered coil car and a servo feed/pull through straightener and motorized uncoiler.

Servo driven feeds share many of the advantages with the press driven variety, such as minimal space requirement, low maintenance, and high speeds. However, servo feeds also provide benefits that press driven units cannot. The fact that they utilize a microprocessor based control gives them an added dimension. Features such as programmable move patterns, self diagnostics, auto correction, and the ability to communicate with automation - just to name a few - set them apart from other types of feeds.

Servo drives have been used for positioning applications in manufacturing for a couple of decades. The technology has matured to the point that these drives are more reliable and less expensive than they were in the past. The number of domestic and foreign manufacturers has increased dramatically in the past few years. The increased reliability, modularity, and self-diagnostic features of servo systems has done a lot to ease the fears that existed earlier, although even now it may still require a considerable degree of technical expertise to isolate some problems.

 

 

III. Technical data:

Meterial               cold roll steel

Coil Weight:               5,000KG

Strip Width:               MAX 1000MM

Strip Thickness for capacity: 0.5-2.5mm

Coil O. D:                      1500 mm (max)

Coil I.D:                508mm (max)

Feeding Accuracy:            + 0,15 mm

Feed length input        9999.99mm

Feed Speed:             15 m/min  

Electrics:                   380 Volts 50 Hz.

Feeder power            servo motor AC 7.5KW

 

 

VI. LIST OF EQUIPMENTS UNDER SCOPE OF SUPPLY:

1. Coil car
2. Decoiler
3. Snubber Roller (Guiding Equipment)
4. entry strip device.
5. Loop senor
6. Side Guide Roller I
7. feeder and straightener
8. Releasing functioning
9. Side Guide Roller II
10. Electrical System.
11. pnematic system
12. hydraulic system

VII. Machine partsproposal .

1. Entry coil car (optional)

 

 

Application

The entry coil car will be hydraulically actuated. It will be used to Traverse and load coil onto the mandrel of the decoiler.
To gain time while working, new coil is loaded to the coil car and lifted to the mandrel position by hydraulic lift and the coil car start to move horizontally let the mandrel go inside through the coil Then the loading car moves to the park position.
Construction:
The coil car is a fabricated body of prime materials; mounted on hardened wheels and axles with spherical roller Bearing. The lifting face must be of ‘V’ shaped design. The cradle (i.e. V – Shape frame) is raised and lowered by a Guide rail and a pair of hydraulic cylinders. The coil car traverse is accomplished by a electrical motor with a gear and pinion drive. A drag chain is provided for routing the hydraulic hoses for lift and traverse functions and Drag Chain is provided
Technical Data:
Type of Coil Car       : Guide Type, Floor mounted
 Lift / Lower function : By hydraulic cylinders with four Colum
Lift stroke            : 350mm
Capacity             : 5000kg

2  Snubber Roller in the hold down arm (Guiding Equipment):

 

Application

Anti coil break roll and guiding the coil to the coil line.

It will operate with the decoiler and the coil peeler to feed-up the coil end. The roll will be bear on the top of the coil, restraining the outer wrap and driving it forward.

A motor is driven Snubber, (pressure roller) to prevent the coil from clock springing when the coil retention straps are removed. Grooves are required on the snubber, to enable re-strapping of partially consumed coils when they are rewound on the mandrel. The Snubber will be capable of driving in both feed and retrieve directions.

 

Construction:

Snubber Roll is made out of Steel Pipe with suitable journals duly machined to be mounted on anti-friction bearings. The Snubber Roll is coated with Poly rubber. Poly roll is driven by electrical motor with chain & sprocket system. Snubber Roll and its Drive system is fitted on fabricated structure which in turn is mounted on the adjacent structure of Pinch Roll body. Actuation of arm is by hydraulic cylinder. The raise and lower functions shall accomplish by a hydraulic cylinder.

Anti coil break roll

To avoid coil breaks during threading the coil and roll will be positioned by hydraulic cylinders with threading table unit.

The strip shall be threaded onto the Line in a semi-automatic manner, using coil opener with various movements like up/down forward/reverse, & opener nose with rotation type.

Technical Data :

• Coating on Snubber Roller    : Poly Coated
• Actuation of arm:           : hydraulic cylinder

 

3 Decoiler (Hydraulic Expanded):

Application

The decoiler can handle the coil and be capable of feeding the coil into the coil Line, and also rewinding partially consumed coils, so they can be re-strapped whilst still on the mandrel, before returning to Coil Storage Facility for use at a later date.

Decoiler is motorized with an expanding mandrel by hydraulic means. Forward and reverse operation of the mandrel will be possible by manual and automatic means. A coil car shall be provided to load the coil to the mandrel.

 

Construction:

Decoiler hydraulic expanded & collapsed, Steel fabricated duly machined, mounted on heavy duty shafts on anti-friction bearings. Expansion – collapse by Hydraulic cylinders. The individual body of fabricated steel construction

Expansion: hydraulic equipped with actuated 4 segments link type wedge.

Technical Data:

• Mode of Operation :  by Hydraulic Cylinder
• Inner Diameter    : Ø460-520 (Max.)
• Outer diameter    : 1800mm
• Capacity loading   : 5000kg

 

4. Loop sensor control:

Application

It has a electrical eyes senor to control the

decoiler and straightener working. It can keep peace the working speed for the decoiler and straightener. The entry loop will create a buffer zone for easier centering for next stage process. Light source and sensors is provided for sensing the loop position.

 

5. Entry support device:

the threading table can be threading the strip and Control by pneumatic.

 

6. Mechanical side guide.

 

Application:

Width shall be adjustable manually with hand-wheel and movement shall be

accomplished by guiding shaft with Left Hand & Right Hand Thread on the same shaft and guide the coil to the straightener

 

Construction:

A fabricated body with roller mounted vertically at two sides (2 Nos. rollers each side). Roller is mounted vertically.

• Adjustment         : manual
• Lubricant           : Grease gun

 

7. straightener and Feeder

Application

The straightener can flatten the coil steel and feeder setting

 

Construction:

straightener is welded steel plate base and “H” Type machine structure.

The body of the Pinch Roll shall be fabricated out of prime plates and machined to house the roll assemblies. The top roll and the button roll deflect the strip from Uncoiler to suit the pass line. The upper roll actuate up and down by means of a pair of pneumatic cylinders. Straightener is provided with hardened gears (60 degree HRC), hardened rolls (42CrMo) Bearings provided for rotary function is Needle Roller Bearings and is grease lubricated automatically.

The upper frame and therefore the upper bank parallel movement to adjust the rolls penetration according to the material thickness by manual with micro indicator.

The upper frame is horizontally pivoted, i.e. it can rotate around a horizontal axis perpendicular to the line axis to allow a deeper penetration of the entry rolls.

The carrying structure of the machine is well dimensioned according to the deformation and holds the upper frame movements.

In feeder Rollers; Top roll and Bottom roller is Hard Chrome Plated. The top roll is actuate up and down by a pair of pneumatic cylinders. The bottom roll must be driven by a servo motor. The feed roller assembly is with Servo Motor driven which will give the sense of length to be feed. The roller shall be lifted and lowered by a pneumatic cylinder or release function

Straightener and feeder rolls are driven via AC servo motor drives motor, gearbox, shaft.

 

Technical Data:

• Straightener Work Roll:  Quantity of Rolls – upper4/ lower3 pieces
  • Material – 42CrMo .
  • Hardness – 52 to 60HRC
  • Plating – Chrome Plating
  •  Model TNCF5-1000,
  •  Width max. 1000mm;
  •  Pinch Roll 1 set ( Upper/ Lower);
  •  Feed Roll 1 set (Upper/Lower);
  • Speed 15 meters per min;
  •  Feed Level from floor 1100-1200. 

 

 

8. Releasing and clamping by Pneumatic

 

To release the upper roller at any stroke of the press in presence of the cam.

 Pilot pin release

Pilot release is the act of momentarily releasing the strip to allow it to be aligned by pilot pins in a progressive die. The pins in the die will correct for slight

mis-feeds by pulling the material back into position. This feature is used primarily with progressive dies but it can be beneficial in applications that don't use non-progressive dies as well. A small amount of misalignment or camber can be tolerated by releasing the material at the bottom of the press stroke while it is held by the tool even if there are no pilot pins. This momentary release helps relieve built up stress and binding of the strip through the feed due to misalignment or camber and alleviates walking problems.
 

 

9.  Mechanical side guide II for output

 

Application:

Width shall be adjustable manually with hand-wheel and movement shall be

accomplished by guiding shaft with Left Hand & Right Hand Thread on the same shaft and guide the coil to the press

 

Construction:

A fabricated body with roller mounted vertically at two sides (2 Nos. rollers each side). Roller is mounted vertically.

• Adjustment         : manual
• Lubricant           : Grease gun

 

 

10. Electrical System:

The system has a complete control of the equipment by means of one programmable PLC

The system is provided with a PLC in the main control desk like HMI (Human Machine Interface). The parameters of work are incorporated in the HMI and communicated with the PLC.

Operator Interface (HMI)

Since the major components of the Automation metal coil line solutions are on Control Net™, all process and diagnostic information is available for display and interaction with the operator. By pre-programming these displays into proven user-friendly designs, we’ve made complex HMIs affordable. Machine is supplied with the following screens:

Machine Overview –

Increases efficiency by providing the operator a visual display of drive and machine parameters in both a bar graph and digital format.

Fault Summary – This screen identifies alarms and faults. When a fault occurs that causes the line to shut down, all faults are identified and the first fault flashes.

Line Run Permissive – The line run permissive screen lists all drives, auxiliary

and other associated equipment required to start the coil line.

Automated Stop On Length or Diameter Set-up – The operator sets up the automated

stop on length or diameter counters via this screen.

 

11. Hydraulic System

One hydraulic Power Pack with stand-by pump is provided for the hydraulic functions in the line and it will remain in our scope of supply which is as follows.

Hydraulic Power Pack is consist of:

• Standby pumping unit and cylinder

• Standard accessories like temperature switch, filler and breather, etc.

Control valves

• The control valves for each equipment or group of equipment is mounted on the respective equipment and piping.

• Each control valve / group of valves is provided with an isolating valve on the ’P’ line and Check valve on the ‘T’ line for ease of maintenance.

• Pressure switch is provided for Uncoiler expansion cylinder for interlock

 

12. Pneumatic systems:

Pneumatic controls is used at various equipments for actuations. Pneumatic control valves is mounted on individual equipment and piped.

The pneumatic systems is consist of following.

• The piping on equipment shall consist of necessary flexible piping with push in type of fittings for easy maintenance.

Standby pumping unit and cylinder

 

 

13. The system layout drawing (in attach)

 

Working pictures

 

Coil car

Loading

Decoiler and snubber arm

 

Coil threading

Staightener and feeder

Pass line adjustable

PLC and servo drives in the Electrical control table

Electrical control table with touch panel