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Posted on Apr 24, 2021
The basic elements in a gear decoiler include the motor-powered payoff, the proportional drag brake, the hold-down arm, the wheel or disc-style keeper arm, the coil guard, the base traverse, and the spool decoiler. The powered payoff utilizes the electric motor to supply the material at line speed or jog speed. The brake can help the gear decoiler to control the strip tensions when the diameter of the coil reduces during the process.
A gear decoiler also called a decoiling machine or uncoiler is an automatic coil handling machine. The main goals of the gear decoiler include unwinding the steel coil, feeding the metal sheets, adjusting the amount of the end material to regulate the capacity of the production line. A gear decoiler can continuously feed the coil sheet which it unwinds into a wide variety of running machinery. For example, automatic punches or almost all the roll forming machines like pressing curve roll forming machine and channel roll forming machine, or slitter, cutter, leveling and cutting to length machine and so on. In these coil handling processes, a decoiler machine is an essential part of the cut to length and feed line.
A gear decoiler machine is preferred across the industry since it is available with almost all types of coil material feeding, it is very common to see a gear decoiler that incorporates a straightener. It provides an inexpensive solution for light-duty uncoil applications. Some gear decoiler machines equipped with speed control systems as well as automatic (or manual) turning capability in different directions. Common stop systems used in gear decoiler machines are friction or pneumatic. The size and load capacity of the gear decoiler machine varies. The operators should identify the following factors of the materials to select the best suitable gear decoiler: the weight of the coil sheet, the inner diameter as well as the outer diameter of the coil, the width of the coil, the minimum and maximum thickness, the speed of the roll forming machines or other downstream running machines.
The operator can reduce the changeover times significantly with a gear decoiler. Without a gear decoiler machine, they might have changeovers 6 to 8 times or more per day depending on the size of the coil materials. Always having a second coil waiting on the line to feed into the downstream running machine removes the urgent need for a crane to load the material when the previous one is out of material. As a result, the gear decoiler plays a critical function in a wide range of roll-forming production lines, particularly in large volume manufacturing lines where the roll formers may run to shape the products across an 8-hour shift. The gear decoiler, in that case, can effectively reduce the downtime for the operators.
The basic elements in a gear decoiler include the motor-powered payoff, the proportional drag brake, the hold-down arm, the wheel or disc-style keeper arm, the coil guard, the base traverse, and the spool decoiler. The powered payoff utilizes the electric motor to supply the material at line speed or jog speed. The brake can help the gear decoiler to control the strip tensions when the diameter of the coil reduces during the process. The keeper arm is typically a single-wheel keeper which is attached to the mandrel. After loading the coil, the keeper arms require the operator to clamp them on the segments. The coil guard is the component used to house the coil clock spring to prevent strips of materials from hitting the workers who walk on the backside. As for the decoiling element, the spool decoiler which the shaft with a single center permits the decoiler machine to handle spools of coil instead of bare coils. The spool decoiler can also be replaced by an expansion system. This important part enhances coil change time and allows the operator to handle the materials safely and easily.
To begin the coil handling and feeding process in a decoiler machine, the coil materials are placed on the device called coil car. The raw material will be loaded into the mandrel and the components will unwind the sheets in order to feed into the cut to the length production line or press parts. The machine arm, which is typically driven by pneumatic pressure, can hold the tip of the materials in the beginning stage of the decoiling process. The coil car which carries the coil materials can move on the rail of the decoiler to get to the commanded positions, the movement is typically driven by a hydraulic motor. The mandrel which gripped the coils firmly is also powered by a hydraulic system, either. The overall coil loop is regulated by 2 photocells and ultrasonic sensors.
When it comes to gear decoiler, the decoiler machine usually handles relatively light-duty coil applications. The gear decoiler is suitable for coil handling applications with loads up to 1000 kg per mandrel. Utilizing a hand ratchet system, the coil which is relatively light in weight will be clamped on the inner diameter. The hand ratchet system can provide expanding and collapsing function on the inner diameters of various coil materials. This system can replace a hydraulic system in order to reduce the costs as well as space consumption. When a gear decoiler machine is incorporated with a precision straightener, the gear decoiler can be very helpful with impressive coil handling control. The gear decoiler can handle and feed strips of greatly thin or low yield strength metals precisely without any damage to the materials with an electric motor. The benefits can reduce the tension in the materials which are generated between the straightener and the gear decoiler as the straightener pulls off the coil. The consistent and efficient feeding cycle between the gear decoiler or other devices, roll forming machines are maintained and powered by the electric motor-driven payoff.
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