1 coil feed systems bruce grant coe press equipment corp

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Coil Feed SystemsCoil Feed Systems

Bruce GrantCoe Press Equipment Corp.

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AgendaAgenda

Coil Feed SystemsCoil Feed Systems Considerations For SelectionConsiderations For Selection UnwindingUnwinding StraighteningStraightening Slack LoopsSlack Loops FeedingFeeding Question And AnswerQuestion And Answer

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Coil Feed SystemsCoil Feed Systems

Selection Determines:Selection Determines: VersatilityVersatility ProductivityProductivity Floor SpaceFloor Space

Variety Of SolutionsVariety Of Solutions

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Considerations For SelectionConsiderations For Selection

Speed RequirementSpeed Requirement Floor SpaceFloor Space Purchase PricePurchase Price Energy and Energy and

Maintenance CostMaintenance Cost SafetySafety

Coil WeightCoil Weight Range of Materials Range of Materials Material Finish Material Finish Run Time Between Run Time Between

ReloadingReloading Loading/Threading Loading/Threading

Time Time

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System ComponentsSystem Components

UncoilerUncoilerStraightenerStraightenerSlack LoopSlack LoopFeedFeed

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Uncoiler TypesUncoiler Types

The 3 most common types of uncoilers.The 3 most common types of uncoilers.

Coil CradleCoil Cradle Centering ReelCentering ReelPallet ReelPallet Reel

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Coil Cradle: ConceptCoil Cradle: Concept

The Coil Is Supported On RollersThe Coil Is Supported On Rollers Medium to Heavy Gauge MaterialsMedium to Heavy Gauge Materials Materials Not Sensitive To MarkingMaterials Not Sensitive To Marking

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Coil Cradles - AdvantagesCoil Cradles - Advantages Coil Weight prevents clock-spring.Coil Weight prevents clock-spring. Unlimited weight capacity.Unlimited weight capacity. Payoff speed does not vary as coil Payoff speed does not vary as coil

diameter changes.diameter changes.

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Coil Cradles - DisadvantagesCoil Cradles - Disadvantages

Marking and distortion of thin or Marking and distortion of thin or cosmetically sensitive materials.cosmetically sensitive materials.

Not suitable for rewinding and re-Not suitable for rewinding and re-banding partially run coils.banding partially run coils.

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Coil Cradles - 2 Basic StylesCoil Cradles - 2 Basic Styles

Inline StyleInline Style Combination Combination StyleStyle

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Inline Style CradleInline Style Cradle Unwinds coil from Unwinds coil from

the bottom.the bottom. Payoff is away Payoff is away

from the press.from the press. Easier to thread.Easier to thread.

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Inline Style CradleInline Style CradleSpace SaverSpace Saver

Overhead loop Overhead loop uses vertical uses vertical space instead of space instead of floor spacefloor space

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Combination Style CradleCombination Style Cradle

Unwinds coil from top.Unwinds coil from top. Pays off through a powered Pays off through a powered

straightener into conventional loop.straightener into conventional loop.

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Unobstructed access for loading.Unobstructed access for loading. Allows use of a load ramp for fast coil Allows use of a load ramp for fast coil

change.change.


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ThreadingThreading More difficult to thread thick or high strengthMore difficult to thread thick or high strength

Floor SpaceFloor Space Requires more floor space due to its conventional loop Requires more floor space due to its conventional loop

configuration.configuration.


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Pallet Reels: ConceptPallet Reels: Concept

Coils are Coils are stacked on a stacked on a turntable and turntable and unwound laying unwound laying on their sideon their side

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Narrow materialNarrow material Thin materialThin material Low strength Low strength

materialmaterial Where marking is Where marking is

not a concernnot a concern

Pallet Reels: ApplicationsPallet Reels: Applications

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LoadingLoading Coils can be stackedCoils can be stacked No need to upend No need to upend

narrow coilsnarrow coils Space SaverSpace Saver

Loop is contained Loop is contained around and above around and above coil and does not use coil and does not use much floor space.much floor space.

Pallet Reels: AdvantagesPallet Reels: Advantages

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Limited material Limited material Width CapacityWidth Capacity

Strip must transition Strip must transition from vertical to from vertical to horizontalhorizontal

Payoff Rate Payoff Rate Changes With Coil Changes With Coil DiameterDiameter

Pallet Reels: DisadvantagesPallet Reels: Disadvantages

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Clock spring DangerClock spring Danger Limited to light gauge, Limited to light gauge,

low strength materialslow strength materials Threading aides for Threading aides for

thick or high strength thick or high strength material are not material are not normally availablenormally available

YOW!!YOW!!

Pallet Reels: DisadvantagesPallet Reels: Disadvantages

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Centering Reels: ConceptCentering Reels: Concept

Coil is held by its Coil is held by its inside diameterinside diameter

Most common Most common method of unwindingmethod of unwinding

Available in a variety Available in a variety of configurationsof configurations

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Centering Reels: ApplicationsCentering Reels: Applications

Can accommodate a wide Can accommodate a wide variety of materialsvariety of materials

No contact with outer No contact with outer wraps of material as wraps of material as unwoundunwound

Great for non-marking Great for non-marking applicationsapplications

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Options available to safely and effectively thread Options available to safely and effectively thread thick or high strength material.thick or high strength material.

Allows rewinding, banding and removal of partially Allows rewinding, banding and removal of partially run coils.run coils.

Clockspring Guard

Hold Down With Motorized Wheel

Peeler

Breaker

Centering ReelsCentering Reels

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Motorized units with loop Motorized units with loop control for payoff into control for payoff into slack loop.slack loop.

Used where straightening Used where straightening is not required or can be is not required or can be used with pull through used with pull through straighteners or straighteners or feeder/straightener units.feeder/straightener units.

Centering Reels: PoweredCentering Reels: Powered

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Known as “Pull Off Reels”Known as “Pull Off Reels” Pinch rolls or powered Pinch rolls or powered

straightener pulls material straightener pulls material off coil off coil

Requires a drag Requires a drag tensioning device tensioning device prevents coil overrunprevents coil overrun

Centering Reels: Non-PoweredCentering Reels: Non-Powered

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Fixed position.Fixed position. Coil must be Coil must be

centered on mandrel centered on mandrel when loaded.when loaded.

Centering Reels: StationaryCentering Reels: Stationary

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Reel runs on a trackReel runs on a track Allows realignment Allows realignment

after the coil has after the coil has been loaded and been loaded and threaded.threaded.

Can run multiple Can run multiple coilscoils

Centering Reels: TravelingCentering Reels: Traveling

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Great for quick coil Great for quick coil changeschanges

Great for running Great for running partial coilspartial coils

Requires more Requires more floor spacefloor space

Centering Reels: Double EndedCentering Reels: Double Ended

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Dual Cone/Double Stub ArborDual Cone/Double Stub Arbor Used for very Used for very

heavy or very wide heavy or very wide coils, with small coils, with small inside diameters.inside diameters.

Support at both Support at both ends prevents ends prevents mandrel mandrel deflection.deflection.

Can reposition coil Can reposition coil after threadingafter threading

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StraighteningStraightening

PurposePurposeTo remove unwanted material shape To remove unwanted material shape

defectsdefects

RequirementsRequirementsVary per application depending on the Vary per application depending on the

material defects present, the design of material defects present, the design of the die and the finished part the die and the finished part requirements.requirements.

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Bend the material around sets of rollers to Bend the material around sets of rollers to alternately stretch and compress the upper alternately stretch and compress the upper and lower regions to and lower regions to exceed the yield pointexceed the yield point so that all surfaces are the same length so that all surfaces are the same length after spring back.after spring back.

Straightening: ConceptStraightening: Concept

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StrainStrain Elastic ModulusElastic Modulus StressStress Elastic LimitElastic Limit Yield PointYield Point SpringbackSpringback

Straightening: ConceptStraightening: Concept

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The result of winding strip into a coilThe result of winding strip into a coil Length difference between top and Length difference between top and

bottom surfacesbottom surfaces Results in curved shapeResults in curved shape

Straightening: Coil SetStraightening: Coil Set

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Effectiveness is a function of roll center Effectiveness is a function of roll center distance, number of rolls and power distance, number of rolls and power availableavailable

StraighteningStraightening

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Precision LevelerPrecision Leveler StraightenerStraightener

Straightening: MethodsStraightening: Methods

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Precision LevelerPrecision LevelerMaterial Conditions CorrectedMaterial Conditions Corrected

Coil SetCoil SetEdge WaveEdge WaveCenter BucklesCenter BucklesCrossbowCrossbowCoil BreaksCoil BreaksDeep Stress ReliefDeep Stress Relief

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19 to 21 work rolls 19 to 21 work rolls Small diameter Small diameter

rollsrolls Very close roll Very close roll

center distancecenter distance Adjustable flights Adjustable flights

of backup rollsof backup rolls

Precision LevelerPrecision Leveler

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Removes coil set and Removes coil set and minor crossbow onlyminor crossbow only

Typically 5 to 11 work Typically 5 to 11 work rollsrolls

Larger roll diameterLarger roll diameter Wider roll spacingWider roll spacing Backup rolls not Backup rolls not

adjustableadjustable

Straightener/FlattenerStraightener/Flattener

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Available in various roll configurationsAvailable in various roll configurations5, 7, 9 and 11 roll versions5, 7, 9 and 11 roll versionsAdditional roll sets allow running entire Additional roll sets allow running entire coil without readjustment of straightening coil without readjustment of straightening rollsrolls


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Pull Through StraightenersPull Through Straighteners Non-driven rollersNon-driven rollers Located after the loop Located after the loop Material is pulled through the straightener by Material is pulled through the straightener by

the feederthe feeder

Powered StraightenersPowered Straighteners Driven rollersDriven rollers Located before the loopLocated before the loop Often used to pull material off of the coilOften used to pull material off of the coil


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Inexpensive and compactInexpensive and compactAllows shorter loop lengthAllows shorter loop length

Straightener: Pull ThroughStraightener: Pull Through

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Pull Through Straightener DisadvantagesPull Through Straightener Disadvantages Material markingMaterial marking Slippage and inaccurate feed lengths Slippage and inaccurate feed lengths Requires power from the feeder for Requires power from the feeder for

straightening. straightening. Limits material capacityLimits material capacity Decreases feed speedsDecreases feed speeds Less effective pilot releaseLess effective pilot release

Straightener: Pull ThroughStraightener: Pull Through

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Straightener: PoweredStraightener: Powered

Advantages:Advantages:Less markingLess markingHigher production speeds Higher production speeds Greater material capacityGreater material capacityStraightener/FeedersStraightener/Feeders

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Slack Loop: PurposeSlack Loop: Purpose Material storageMaterial storage to supply the feed while the to supply the feed while the

unwinder accelerates to line speedunwinder accelerates to line speed To absorb and store material while the coil To absorb and store material while the coil

decelerates after feeding stopsdecelerates after feeding stops To allow the coil to run at a constant speedTo allow the coil to run at a constant speed

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Slack LoopSlack Loop

TypesTypes HorizontalHorizontal OverheadOverhead PaddlePaddle

Horizontal Loop

Paddle Loop

Overhead Loop

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The amount of material stored is equal to The amount of material stored is equal to the total slack length minus the straight the total slack length minus the straight line length. line length.

Straight Line Length

Slack Length


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If the material is straightened prior to the loop If the material is straightened prior to the loop then the radius of the loop cannot be smaller then the radius of the loop cannot be smaller than the than the Minimum Bend Radius Minimum Bend Radius for the thickest for the thickest material that will be run on that line.material that will be run on that line.


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The strip must be supported into and out of the The strip must be supported into and out of the loop by cascade rolls at both ends.loop by cascade rolls at both ends.

Without support the weight of the loop will cause Without support the weight of the loop will cause the material to be bent beyond its minimum bend the material to be bent beyond its minimum bend radius resulting in material that is no longer flat.radius resulting in material that is no longer flat.


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Gripper FeedsGripper Feeds Roll FeedsRoll Feeds

Press Driven Press Driven Servo DrivenServo Driven Straightener/FeederStraightener/Feeder

Feeds: TypesFeeds: Types

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Uses linear motion to move the stripUses linear motion to move the stripUses clamping mechanisms to hold Uses clamping mechanisms to hold

and move the stripand move the strip

Feeds: GripperFeeds: Gripper

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Powered by: Powered by: Compressed airCompressed air HydraulicHydraulic Servo Drive and Servo Drive and

Ball ScrewBall Screw

Feeds: GripperFeeds: Gripper Applications:Applications:

Slow To Medium Slow To Medium SpeedsSpeeds

Medium to Heavy Medium to Heavy gauge materialsgauge materials

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Advantages: Advantages: Low acquisition priceLow acquisition price Mechanically and electrically simpleMechanically and electrically simple Accurate if properly maintained and set upAccurate if properly maintained and set up Widely used with pull through straightenersWidely used with pull through straighteners Flexible feed and pilot release timingFlexible feed and pilot release timing


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Disadvantages:Disadvantages:High maintenance costHigh maintenance costLimited speedsLimited speedsLong set-up timeLong set-up timeHigh operating costHigh operating costMaterial markingMaterial markingLimited feed length capabilityLimited feed length capabilityNo inherent inching capabilityNo inherent inching capability


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Roll FeedsRoll Feeds

Press DrivenPress DrivenServo DrivenServo DrivenStraightener/FeedersStraightener/Feeders

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Rack and Pinion Rack and Pinion FeedsFeeds

Cam FeedsCam FeedsPowered by the Powered by the

presspressSynchronized to Synchronized to

press motionpress motion

Roll Feeds: Press DrivenRoll Feeds: Press Driven

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Applications:Applications:Full range of Full range of

materialsmaterialsHigh speed High speed

applications applications Non-marking Non-marking

capabilitycapability


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AdvantagesAdvantagesHigh cycle ratesHigh cycle ratesSynchronized to Synchronized to

press motionpress motionVery accurateVery accurateMechanically and Mechanically and

electrically simpleelectrically simple


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DisadvantagesDisadvantagesMechanical linkage to pressMechanical linkage to pressLimited feed length capabilityLimited feed length capabilityLimited adjustment of feed Limited adjustment of feed

timingtimingNo inherent inching No inherent inching

capabilitycapability


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Powered By A Closed Loop Servo DrivePowered By A Closed Loop Servo Drive Microprocessor Based Motion ControlMicroprocessor Based Motion Control

Roll Feeds: Servo DrivenRoll Feeds: Servo Driven

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Applications:Applications:Full range of materialsFull range of materialsNon-marking capabilityNon-marking capabilityMedium high speed Medium high speed

applicationsapplications

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Rapid set upRapid set upUnlimited length capabilityUnlimited length capabilityFlexible feed timing and windowFlexible feed timing and windowInherent Inching CapabilityInherent Inching CapabilityLow maintenanceLow maintenanceInterface with press automationInterface with press automation


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Wide variety of configurations Wide variety of configurations and control options:and control options:Synchronization to press motionSynchronization to press motionStep programmability Step programmability Push-Pull FeedsPush-Pull FeedsZig-Zag FeedsZig-Zag FeedsStraightener/FeedersStraightener/Feeders


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Straightener FeedersStraightener Feeders Compact Coil LinesCompact Coil Lines

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ConclusionConclusion

There is no “one size fits all” solution.There is no “one size fits all” solution.Don’t limit your capabilities through Don’t limit your capabilities through

equipment selection.equipment selection.Consider all aspects when selecting Consider all aspects when selecting

your system.your system.

Summary & Conclusion

1 coil feed systems bruce grant coe press equipment corp

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