Hydraulic Uncoiler Detailed Product Description
As a core front-end equipment in metal coil processing production lines, the hydraulic uncoiler focuses on solving problems such as automatic feeding, precise tensioning, stable uncoiling and closed-loop tension control of heavy coils. It is compatible with various material coils including steel strips, aluminum sheets, pre-painted coils, stainless steel sheets and galvanized sheets, and is widely used in industrial scenarios such as color steel tile roll forming, high-precision sheet leveling and cutting, auto parts stamping, container manufacturing, home appliance shell processing and steel structure production. It is a key equipment to improve the automation level of production lines, ensure processing accuracy and reduce labor costs.
I. Overall Structure and Material Technology
The whole machine adopts a modular design, and the core load-bearing structure is a welded box-type frame or H-beam frame, which is welded and formed with Q355B high-strength steel. After welding, it undergoes integral annealing stress relief treatment, and then is finished and leveled by CNC milling machine to ensure the frame flatness error ≤ 0.05mm/m, eliminating deformation and cracking under long-term heavy-load operation. The rigidity and stability of the machine body are far superior to ordinary welded structures.
The equipment base is integrally formed with thickened steel plates, and anchor bolt installation holes are reserved at the bottom, which can be fixed on the ground by secondary grouting, effectively absorbing vibration during operation and avoiding equipment displacement affecting coil uncoiling accuracy. The surface of the machine body is shot blasted for rust removal and then sprayed with polymer anti-corrosion and wear-resistant paint, which is acid and alkali resistant, rust resistant, suitable for harsh working conditions such as humidity and heavy dust in the workshop, and extends the service life of the equipment.
II. Detailed Explanation of Core Components
1. Hydraulic Expanding Mandrel
The mandrel is the core executive component of the equipment, adopting a four-slider arc plate structure. The arc plate is made of 42CrMo alloy structural steel, which is quenched and tempered (hardness up to HRC28-32) and then hard chrome plated on the surface (plating thickness 0.05-0.08mm). It has high strength, high wear resistance and smooth surface, which can effectively avoid scratching the inner hole of the coil, and at the same time improve the friction force with the coil to prevent slipping.
The expansion drive adopts a double-acting hydraulic cylinder, and the four sliders are controlled to expand and contract synchronously through a precision synchronous valve. The expansion range can be customized on demand (conventional Φ460~Φ520mm, special up to Φ380~Φ650mm) to adapt to coils with different inner hole diameters; the tensioning pressure can be adjusted through the overflow valve of the hydraulic system (range 0.8-16MPa), and appropriate pressure can be matched for thin and thick materials respectively, so as to ensure stable rounding of the coil and avoid deformation of thin materials due to pressure.
2. Drive and Brake System
The drive unit adopts a low-speed and high-torque hydraulic motor with a planetary gear reducer, the transmission efficiency is as high as 95% or more, and the output torque is stable. It can precisely adjust the speed (0-15m/min stepless adjustment) according to the coil weight (5T/10T/20T/30T) and uncoiling speed requirements, adapting to the processing rhythm of different production lines.
The brake system adopts hydraulic disc brake, the brake disc is made of high-strength cast iron, and the brake pad is made of wear-resistant asbestos-free material, which has sensitive braking and good heat dissipation, and the braking torque can be precisely adjusted through the hydraulic system. Cooperating with the feedback signal of the tension sensor, it realizes dynamic brake adjustment when the coil diameter changes, ensuring constant tension during coil uncoiling, eliminating coil loosening, material throwing or tensile deformation, especially suitable for high-precision uncoiling of thin-gauge coils (thickness 0.1-0.5mm).
3. Auxiliary Feeding Mechanism
It is equipped with a standard hydraulic lifting trolley. The trolley table adopts anti-skid checkered steel plate, and the bearing capacity matches the rated coil weight of the equipment (for example, the bearing capacity of the trolley for 20-ton model is ≥25 tons). The lifting stroke is 0-800mm, driven synchronously by double hydraulic cylinders, with stable lifting without impact and positioning accuracy of ±2mm. It can easily lift the coil from the ground to the mandrel height to realize one-button automatic feeding.
An optional side-thrust centering mechanism is available, which is driven by a servo motor and a ball screw with a centering accuracy of ±0.5mm. It can automatically detect the edge position of the coil and adjust the lateral position of the coil through the side-thrust device to ensure no deviation during coil uncoiling and subsequent leveling and cutting, especially suitable for processing wide coils (width 1600-2000mm).
III. Hydraulic and Control System
1. Hydraulic System
It adopts an integrated hydraulic station, and the core components (oil pump, solenoid valve, overflow valve, synchronous valve) are all selected from international well-known brands such as Bosch Rexroth and Eaton. The working pressure of the hydraulic system is 16-25MPa, the flow rate can be adjusted on demand, and it has pressure compensation and overload protection functions. The hydraulic oil adopts anti-wear hydraulic oil (ISO VG 46), equipped with oil temperature cooler, oil level alarm and filter clogging alarm, ensuring long-term stable operation of the hydraulic system without leakage and failure.
For tension control, a hydraulic closed-loop control system is adopted. The tension sensor collects the coil tension signal in real time, feeds it back to the hydraulic controller, and automatically adjusts the speed of the hydraulic motor and the brake pressure to achieve precise tension control (tension control accuracy ±5%). The tension adjustment range is 500-5000N, adapting to the differentiated needs of thin materials, thick materials and coils of different materials.
2. Electrical Control System
The electrical system adopts Siemens S7-1200/1500 series PLC with Kunlun Tongtai/Weinview touch screen. The operation interface is simple and intuitive, supporting Chinese and English bilingual switching, and operators can quickly master the switching of manual, automatic and linked control modes. The manual mode can independently control mandrel expansion, trolley lifting and side-thrust centering, facilitating equipment debugging and maintenance; in automatic mode, the equipment can complete the whole process of automatic feeding, tensioning, centering and uncoiling according to preset parameters without manual intervention; the linked mode can seamlessly connect with subsequent equipment such as levelers, shears and roll forming machines to realize automatic linked control of the production line. It supports remote I/O and production line networking, and can be integrated into the factory MES system to realize real-time monitoring and traceability of production data.
It is equipped with complete electrical protection functions, including overcurrent protection, overload protection, phase loss protection and leakage protection. At the same time, emergency stop buttons (one at the front and rear of the equipment) are set to ensure the personal safety of operators and the stable operation of the equipment.
IV. Safety Protection and Adaptability
1. Safety Protection
The equipment complies with CE industrial safety standards. A detachable protective fence (height ≥1.2m) is equipped outside the mandrel to prevent accidental throwing of the coil during uncoiling; the hydraulic system is equipped with a safety overflow valve, which automatically relieves pressure when the system pressure exceeds the rated value to avoid component damage; the electrical system is equipped with an emergency stop circuit, and the equipment will immediately cut off the power and relieve the hydraulic system pressure when the emergency stop button is pressed, ensuring quick shutdown in emergency situations. In addition, the equipment is also equipped with a coil loosening detection device, which immediately alarms and shuts down when the coil is loose, avoiding the expansion of faults.
2. Customized Adaptability
Customized models can be provided according to customers’ actual production needs, with core customization dimensions including:
- Coil weight adaptation: 5T/10T/20T/30T/50T. For ultra-heavy coils, the frame and mandrel structure can be strengthened, and a hydraulic motor with higher power can be selected;
- Coil specification: inner hole diameter Φ380~Φ650mm, coil width 800~2500mm, and the mandrel length and trolley size can be adjusted;
- Material adaptation: for coils of special materials such as stainless steel and high-hardness alloy plates, the material of the mandrel arc plate can be optimized (stainless steel or ceramic coating spray), improving wear resistance and scratch resistance;
- Function expansion: optional coil automatic detection device (detecting coil thickness, width, surface defects), automatic deviation correction device, waste collection device, etc., to adapt to personalized production needs.
V. Typical Technical Parameters (Conventional 20T Model)
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Parameter Name
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Value
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Rated Coil Weight
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20T (Maximum Bearing Capacity 25T)
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Mandrel Expansion Range
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Φ460~Φ520mm (Customizable)
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Maximum Coil Width
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2000mm
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Coil Thickness Range
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0.1~6mm
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Uncoiling Speed
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0~15m/min (Stepless Adjustment)
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Hydraulic System Working Pressure
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20MPa
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Tension Control Range
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500~5000N (Control Accuracy ±5%)
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Centering Accuracy
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±0.5mm
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Motor Power
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11kW (Hydraulic Pump Motor) + 2.2kW (Centering Servo Motor)
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Equipment Overall Dimensions (Length×Width×Height)
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2800×2200×2500mm (Customizable)
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Equipment Weight
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Approx. 8.5T
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VI. Application Value and After-Sales Guarantee
Through automatic feeding, precise tension control and linked adaptation, the hydraulic uncoiler can greatly reduce labor input (a single equipment can replace 2-3 workers), improve the production line efficiency by more than 30%, and at the same time avoid problems such as coil scratching, deviation and unstable tension caused by manual operation. The processing accuracy is improved by 20%, effectively reducing raw material loss and scrap rate.
In terms of after-sales service, free equipment installation and commissioning and operator training services are provided, with a 1-year warranty period (2-year warranty for core components). Lifelong technical support and spare parts supply are provided, and a 24-hour after-sales service hotline is established to ensure quick response and timely solution when equipment fails, so as to guarantee the continuous operation of the production line.
♦ COMPANY PROFILE:
Hebei Xinnuo Roll Forming Machine Co., Ltd., not only produce different types of professional roll forming machines, but also develop intelligent automatic roll forming production lines, C&Z shape purline machines, highway guardrail roll forming machine lines, sandwich panel production lines, decking forming machines, light keel machines, shutter slat door forming machines, downpipe machines, gutter machines, etc.
Advantages of Roll Forming A Metal Part
There are several advantages of using roll forming for your projects:
- The roll forming process allows operations such as punching, notching, and welding to be performed in-line. Labor cost and time for secondary operations are reduced or eliminated, reducing part costs.
- Roll form tooling allows for a high degree of flexibility. A single set of roll form tools will make almost any length of the same cross-section. Multiple sets of tools for varying length parts are not required.
- It can provide better dimensional control than other competing metal forming processes.
- Repeatability is inherent in the process, allowing easier assembly of roll formed parts into your finished product, and minimizing problems due to “standard” tolerance build up.
- Roll forming is typically a higher speed process.
- Roll forming offers customers a superior surface finish. This makes roll forming an excellent option for decorative stainless steel parts or for parts requiring a finish such as anodizing or powder coating. Also, texture or pattern can be rolled into the surface during forming.
- Roll forming utilizes material more efficiently than other competing processes.
- Roll formed shapes can be developed with thinner walls than competing processes
Roll forming is a continuous process which converts sheet metal into an engineered shape using consecutive sets of mated rolls, each of which makes only incremental changes in the form. The sum of these small changes in form is a complex profile.
