Page 19 - MetalForming August 2011

wear and tear to the equipment, short- ening life cycles.
New Technologies
for Space-Saving Feeders
Space-saving feeds have gained in popularity because they cost less and use less floor space than do conven- tional feed lines. However, many older models have limitations. On average, they cannot match feed speeds and material gauges of conventional lines. However, these older units now can be upgraded.
For example, some stampers make use of dual-function payout systems that provide conventional feed-line production capabilities in a space-sav- ing format. Two selectable automatic loop-control modes on the reel pro- vide this versatility, using a combina- tion of mechanical and control upgrades. This dual-loop function allows the reel and feeder to be syn- chronized to run at the same rate, increasing performance levels and reducing wear and tear of the system.
The forward loop mode maintains the loop between the reel and feed dur- ing an automatic coil run to allow pro- cessing light-gauge material at long feed lengths and at high stroke rates. A laser loop sensor controls the material payout during the automatic coil run.
The back loop mode provides the flexibility to process heavy-gauge mate- rials by maintaining a clock-spring loop to form a free loop beneath the coil, as controlled loop storage for the feeder. The synchronized reel and feeder run at the same speed by replacing the brains and not the brawn.
The dual-function payout system also eliminates the sudden start-stop motions that induce wear and tear on the feeder, avoiding maintenance issues and costs while eliminating acceleration marks on the material.
Synchronized Plug-and-Play Systems
Can a conventional feed line, with old technology that has been in use for many years, be brought up to modern capabilities and standards? The fol-
lowing illustration demonstrates how it can be done. Consider a metalform- ing shop that, in 1985, purchased a new press and equipped it with an air feed—more than satisfactory at the time —as well as state-of-the-art back-end equipment. Fast forward to today, when, as many shops recently have concluded, an aging air feed fails to
The back loop mode maintains a clock-spring loop beneath the coil as controlled loop storage for the feeder.
meet current needs. So, the shop invests in a new servo-drive unit that fea- tures the latest controls and electronics. All that’s needed is to synchronize the straightener and feeder.
Step one: Go to the back end and build a new platform to get an integrated system, in order to synchronize the straightener with the feeder. After 25 years of wear and tear, the brake
on the reel must be rebuilt. Next, install an integration package that monitors brake pressure on the reel using a laser to measure coil OD. With this infor- mation, the control can adjust the speed rate or brake tension in conven- tional lines to avoid having material pulled too tightly or too loosely. As coil OD shrinks, the brake automatically
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The back end of this line features laser loop control, coil-O.D. laser monitoring and a laser light pole for mode detection.