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OUR
CUSTOMERS "When I presented my challenges
to Accra-Wire Controls, it was apparent that the technology
used in tension control and coil handling could really help
us. We are now able to load a shift's production at one time,
eliminating up to nine coil changes." - Monty
BrennerPlant Manager
Pullman Industries
Michigan, USA
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"Pallet
Decoilers Come of Age" by John
Heuring
Magazine
Increased safety and versatility make decoilers profitable production
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We would
change coils up to 15 times per shift, taking 10 to 15 minutes per
change. We knew there had to be a better way." This comment
is unfortunately very common in the industry.
Manufacturers often have lamented over the loss of productivity
due to numerous coil changes and lack of continuos production. Have
you ever wondered if there was a better way?
When the first pallet decoilers came on the market some years ago,
they proved to be a significant advancement. Now, an operator could
run an entire pallet of flat stock and the only downtime involved
is cutting the banding on the coil. No more "up-ending"
coils into place with a crane or hoist. Now one operator could load
30 coils of strip at one time. Even when running only a partial
coil, it was much safer to unload and reload a pallet then to manhandle
the coil.
Unfortunately, the speeds and range of material that these units
could handle were limited. Most could not ramp up with a clutch-driven
roll former. Few could run faster then 100 ft. per min. None could
run material thicker then around 0. 060 in. With limited technology
and poor material control, pallet decoilers gained a reputation
for kinkig and distorting metal prior to processing. Although superb
in concept, pallet decoilers were anything but superb in the "real
world." What would be done to solve this common problem? Had
pallet decoilers "come of age" to the point that the could
handle high demand applications? What about the ramp up time needed
for the mill and the speeds customers would require? Did anyone
have the technology to build a machine that could perform these
demanding operations?
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Teamwork,
Technology, and Tension Control
One company was looking for a pallet decoiler to work with
their roll former. The challenge was that the mill speed would run
in excess of 160 fpm and the material widths ranged from 3.5 in. to
22.125 in. Another consideration was the quick acceleration of the
mill. It was going to be tough to find a pallet decoiler to handle
the job.
As is typical when searching for machinery that is unique, the
team leader had to embark on a "search and find" mission.
This involved much time and commitment as he relates, "I was
placed in charge of finding the equipment. It seemed that no pallet
decoiler manufactuer could do what I requested, in fact, one company
even said that there was no way it could be done."
"We decided to attend the METALFORM '95 trade show to find
the corect machine." They saw a few decoilers available and
did not feel that they would be adequate. But then they found one
that looked promesing. "Accra-Wire Controls (AWC) seemed to
have a design that showed some possibility. They said right from
the start that they would handle the job, but so did some other
companies. The difference was that they explained how they were
going to do it," he states.
The high-torque, shaft-driven system that Accra-Wire Controls employs
provides stable operation, even in demanding environments.
"I was pleased that the engineering staff at AWC was willing
to work with us in designing something specifically for our job,
rather then stating either they could not do it, or that a standard
model would work."
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The
Difference?
What made it work? Constant tension. AWC has patented a tension control
system that helps them to handle highly specialized applications.
"We can run material widths over 22 in. and loads up to 26,000
lbs. We have jobs running narrow strip with thicknesses in the 3/16
in. range and speed capabilities of over 200 fpm," says Johnnie
L. Jones, president and founder of AWC. "We welcome the opportunity
to try a customer's material in-house to determine if we can run the
operation. We then will provide a personalized video for our customer
which we use to explain our ideas and means of doing the job properly.
This gives the customer an understanding of the machine they are considering.
Summarizing the results of the pallet decoiler, the team leader
relates, "We have experienced a 22 percent increase in production.
We use more of our shift running material rather than changing coils
and our parts have become more precise as the material tension is
maintained. We also have the added safety of not having to hand
load coils anymore." It took two operators to run the mill
before getting the AWC decoiler. They now look forward to reducing
that to one operator.
AWC has proven their versatility with hard-to-handle applications.
But how can this technology assist the majority of manufacturers
working with standard materials and operations? Another case history
will prove informative.
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Production
Increases, Downtime Decreases
Monty Brenner is a 33-year tenured plant manager at Pullman Industries,
manufacturers of automotive components with three plants in Michigan.
His challenge, as Monty said, "was to increase production and
safety for my operators." In his hunt for the solution, Monty
indicated "all arrows kept pointing to pallet decoiling,"
and he added, "sometimes having more than nine coil changes
per day for each of the many roll form lines we have, there had
to be a better way."
"When I presented my challenge to AWC, it was apparent that
the technology they used in tesion control and coil handling could
really helps us. By using their decoilers, switching to larger OD
coils and making some changes in the roll formers' controllers,
we have been able to produce four times the amount of parts (most
of the increase came from the reduction in coil changing and the
use of larger coil Ods.) After running the lines it became evident
that we also going to save on labor costs. Now,one operator can
run two mills simultaneously."
With the patented process AWC uses, the desire for increased production
is attained. Applying inertia formulas especialy formulated for
pallet decoiling allows AWC to mach the pallet decoilers to the
line speed and skid weights of the applications.
"When dealing with increased weight and speed," explains
Paul Siegel, sales manager for Accra Wire Controls, "you need
horsepwer, tension control and rugged construction in your pallet
decoiler. This allows you to power up and down (e-stop) with the
big loads.)
Other design and operating features are worth nothing. Tension control
and quick acceleration/deceleration are based on AWC's electronically
controlled regenerative DC drive which eliminates the need for clutches,
brakes and maintenance. As the roll mill calls for material the
"control arm" senses the demand and will mirror the speed
required. The material then flows along its natural helix through
the giude rollers providing smooth decoiling.
Containment of material that could be running over 250 ft./min.
is imperative. The mass of coils generates enormous inertia, which
makes necessary the "table centering stem system" that
AWC employs. It also prevents coil "pigtails" at the ID
from pulling off the top of or droping into the center of the remaining
coils, thus reducing the chance of damaging accidents.
Overall, it is clear that pallet decoilers have finally
"come of age." The benefits gained through pallet decoiling
have shown that these units are cost-effective. Their versatility
now proves them to be practical for most stamping and roll forming
operations.
REPRINTED FROM THE JANUARY 1996 ISSUE
OF MetalForming MAGAZINE
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Consult
AWC for the right choice for YOUR application. |
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