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"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

 

ARTICLES
 
Stamping Quarterly Article
"Deciding When to UsePallet Decoilers"
The Fabricator Article
"Applying Pallet Decoilers to Roll Forming Applications"
Metal Forming Magazine article
"Pallet Decoilers Come of Age"
Stamping Journal Magazine article
"Sizing Up Pallet Decoilers"
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"Pallet Decoilers Come of Age" by John Heuring
Magazine

Increased safety and versatility make decoilers profitable production partners
 

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?


 
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."

 
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.

 
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

 
Consult AWC for the right choice for YOUR application.

AWC is a Member of:
Fabricators & Manufacturers Association Precision Metalforming Society of Manufacturing Engineers

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