Uncoiler

Details of Equipment Structure

Part: Reel

Structure Types: The reels of decoilers have various structures. For example, the expanding and contracting type reel can change its diameter through hydraulic or mechanical devices to adapt to coils with different inner diameters. The internal expanding and contracting mechanism can precisely control the outer diameter of the reel to ensure a tight fit with the inner hole of the coil. Generally, it can adapt to the inner diameter range from 50mm to 600mm.

Materials and Strength: The reels are usually made of high-strength alloy steels, such as 42CrMo and other materials. This kind of material has high strength and toughness, capable of withstanding the weight and tension of heavier coils. The surface of the reel may undergo special treatments, such as chrome plating or spraying wear-resistant coatings, to increase the wear resistance of the reel and the friction between the coil and the reel, preventing the coil from slipping during the unwinding process.

Transmission System

Power Source: Generally, the power is provided by an electric motor. The power of the motor depends on factors such as the specifications of the decoiler and the weight and thickness of the coil. For example, for a decoiler used to process heavier metal coils, the power of the motor may range from 10kW to 50kW. The motor is connected to a reducer through a coupling, and the reducer can adjust the output rotational speed to meet different unwinding speed requirements.

Transmission Precision: The precision of the transmission system is crucial for the stable operation of the decoiler. High-precision gear or belt transmission methods can ensure the uniform rotation of the reel, reducing vibration and speed fluctuations. Some high-end decoilers adopt precision planetary reducers and synchronous belt transmissions, and the unwinding speed error can be controlled within ±0.1m/min.

Supporting Devices

Bearing Block: The bearing block used to support the reel is a key component. High-quality bearing blocks are made of cast steel or cast iron and are precisely machined to ensure the fitting precision with the bearings. Bearings usually select self-aligning roller bearings or tapered roller bearings, which can withstand axial and radial loads to ensure the stability of the reel during rotation.

Frame Structure: The frame is the overall supporting structure of the decoiler, usually welded by steel plates and annealed to eliminate welding stresses. The design of the frame should take into account the distribution of the center of gravity of the equipment and the overall stability. In large decoilers, the frame may adopt structures such as reinforcing ribs to increase strength and prevent deformation during the operation of the equipment.

Details of Functions

Function of Coil Unwinding

Adjustment of Unwinding Speed: The unwinding speed of the decoiler can be adjusted according to production requirements. In the manual adjustment mode, operators can adjust the unwinding speed within a certain range (such as 0 - 50m/min) by turning the speed adjustment knob on the operation panel. In the automatic mode, the decoiler can automatically adjust the speed according to the collaborative work requirements with subsequent equipment to achieve efficient operation of the production line.

Positioning and Centering of Coil: To ensure that the coil can accurately enter subsequent processing equipment during the unwinding process, the decoiler is equipped with a coil positioning and centering system. This system usually adopts photoelectric sensors or mechanical centering devices, which can detect the edge position of the coil and adjust the lateral position of the reel to make the center of the coil consistent with the center line of the equipment. The centering precision can reach ±1mm.

Tension Control Function

Tension Detection Method: The tension of the coil is detected by tension sensors. The tension sensors are installed at appropriate positions on the path of the coil, such as between the reel and the guide roller. They can measure the tension magnitude of the coil in real time and feed back the signal to the control system. Common tension sensors include strain gauge type tension sensors and magnetoelastic type tension sensors, with a measurement precision of up to ±1N.

Tension Adjustment Mechanism: According to the signal fed back by the tension sensors, the control system will adjust the rotational speed of the reel or control the tension of the coil through braking devices. For example, when the tension is too large, the control system will reduce the rotational speed of the reel or appropriately release the braking device to reduce the tension of the coil; conversely, when the tension is too small, the control system will increase the rotational speed of the reel or increase the braking pressure to restore the tension to the set value. The tension control precision can reach within ±5% of the set value.

Principle of Leveling (if applicable): The decoiler with a leveling function levels the coil by using multiple groups of leveling rollers arranged in an up-and-down staggered manner. The leveling rollers usually adopt high-precision chrome-plated rollers with high surface hardness and good smoothness. When the coil passes through these leveling rollers, the wavy or bent deformation of the coil is corrected through the pressure and bending deformation of the rollers, making the coil reach the required flatness.

Leveling Precision: The flatness of the leveled coil can reach a wave height of no more than ±1mm per meter length, meeting the requirements of most subsequent processing techniques (such as stamping, cutting, etc.) for the flatness of the coil.

Decoiler equipment is mainly used in the following industries:

Steel Industry

Sheet Metal Processing: In steel mills or steel processing enterprises, decoilers are used to unwind large steel coils, providing flat steel plates for subsequent processing operations such as rolling, cutting, and stamping. For example, steel coils after hot rolling or cold rolling are unwound and processed into building steel plates and automotive steel plates of different specifications.

Steel Pipe Manufacturing: It is one of the key equipment in the welded pipe production line. It supports the steel coil by tightening the inner hole of the steel coil and sends the head of the steel strip into the leveling machine, providing the steel strip raw material for the subsequent steel pipe forming process.

Automotive Manufacturing Industry

Automotive Component Production: A large amount of metal sheet is required in automotive production to manufacture body components, engine components, etc. After unwinding the metal coil, the decoiler provides raw materials for the stamping production line to stamp out components such as car doors, engine hoods, and chassis.

Automotive Assembly Line: During the automotive assembly process, some auxiliary materials such as interior materials and soundproofing materials are often supplied in the form of coils. The decoiler can unwind these coils for operations such as cutting and bonding to meet the requirements of automotive assembly.

Home Appliance Industry

Shell Manufacturing: The shells of home appliances such as refrigerators, air conditioners, and washing machines are usually made of metal sheets. After unwinding the coil, the decoiler manufactures variously shaped shell components through processes such as stamping and bending.

Internal Structural Component Production: Some internal structural components of home appliances, such as the evaporator and condenser of air conditioners, also need to be processed from metal coils. The decoiler provides the preliminary coil unwinding service for the production of these components.

Electronics Industry

Circuit Board Manufacturing: In the production process of electronic circuit boards, metal coils such as copper foil are required. The decoiler unwinds the copper foil coil to provide flat materials for subsequent processes such as etching and electroplating, ensuring the quality and performance of the circuit board.

Electronic Equipment Shell Production: The shells of some electronic equipment, such as computer cases and mobile phone shells, are made of metal materials. The decoiler can unwind the corresponding metal coils for use in processing operations such as stamping and forming to manufacture shell products that meet the requirements.

Construction Industry

Steel Structure Manufacturing: In the production of building steel structures, decoilers are used to unwind steel plate coils, cut them into appropriate sizes and shapes for manufacturing structural components such as steel beams, steel columns, and trusses, which are widely used in industrial plants, high-rise buildings, bridges and other construction projects.

Building Decoration: Some building decoration materials, such as color steel plates and metal curtain wall panels, are also produced in the form of coils. After unwinding the coil, the decoiler can perform further processing and treatment such as spraying and embossing to make them into building decoration materials with good appearance and durability.

Mechanical Manufacturing Industry

General Machinery Manufacturing: In the manufacturing process of various general mechanical equipment such as machine tools, cranes, and conveyors, a large amount of metal sheet is required to manufacture components such as machine bodies, workbenches, and conveyor belts. The decoiler provides the basic coil unwinding process for the production of these components.

Special Machinery Manufacturing: For some special mechanical equipment in specific industries, such as mining machinery, agricultural machinery, and textile machinery, decoilers are also needed to unwind the corresponding metal coils and process them into components that meet the requirements of the equipment.

Packaging Industry

Metal Packaging Material Processing: In the production of metal packaging materials such as metal cans and metal boxes, it is necessary to first unwind the metal coil and then perform processing operations such as stamping and welding to manufacture packaging containers of various shapes and specifications.

Label Printing and Bonding: In some label printing enterprises, for self-adhesive label paper or plastic film labels in the form of rolls, the decoiler can unwind the coil for operations such as printing, gluing, and bonding to improve the efficiency and quality of label production.

Shipbuilding Industry

Hull Structure Manufacturing: The hull structure of a ship requires a large amount of steel plate to manufacture. After unwinding the thick steel plate coil, the decoiler assembles the components such as the keel, ship plate, and bulkhead of the ship through operations such as cutting, bending, and welding, and it is one of the important preliminary equipment in shipbuilding.

Ship Interior Decoration and Equipment Manufacturing: Decoilers are also used in the manufacturing of interior decoration materials and some ship equipment. For example, the coils of carpet, wallpaper and other decoration materials are unwound for the interior decoration of the ship; the metal coils are unwound to manufacture equipment components such as railings, handrails, and ventilation ducts on the ship.