How to prevent coils being picked up missed together in coil packing line

The Prevent Multiple Coils from Being Picked Up Simultaneously or Missed Altogether The function of a downender in a steel coil packaging line is to rotate and position steel coils for further processing or packaging. Specifically, it picks up the coil and rotates it 90 degrees, typically turning the coil from a vertical "eye-to-wall" position (where the coil is standing on its edge) to a horizont

The Prevent Multiple Coils from Being Picked Up Simultaneously or Missed Altogether

The function of a downender in a steel coil packaging line is to rotate and position steel coils for further processing or packaging. Specifically, it picks up the coil and rotates it 90 degrees, typically turning the coil from a vertical "eye-to-wall" position (where the coil is standing on its edge) to a horizontal "eye-to-sky" position (where the coil is lying flat). This rotation allows the coil to be wrapped, strapped, or moved more easily along the packaging line.

The downender often includes hydraulic systems for lifting and turning, ensuring smooth and precise positioning. In the context of automated lines, it works alongside other equipment like turnstiles, conveyors, and strapping machines to facilitate efficient, automated handling of heavy coils

In a fully automated steel coil packaging line, preventing errors such as picking up multiple coils or missing coils altogether requires an intelligent control system combined with precise mechanical and electronic components. Here’s how the system ensures accuracy and efficiency during the coil handling process:

1. Inputting Coil Width Information into the Control System

The first step to ensuring that the lifter on the downender only picks up one coil at a time is inputting the correct coil width information into the control system. The downender’s lifter operates according to pre-set parameters that match the size of the coil. This can be achieved in several ways:

A. Manual Input via HMI: The operator manually inputs the coil’s width into the Human Machine Interface (HMI) and saves the coil info list for future reference. This ensures that the lifter adjusts according to the specific dimensions of each coil being processed.

B. Bar Code Scanning and Coil Width Reading: In more advanced systems, bar code scanners read the coil’s width directly from the bar code label attached to each coil, automatically feeding the data into the control system. This eliminates human error in data entry.

C. PLC Data Sharing via Ethernet or Profibus: For lines integrated with upstream slitting processes, the coil width information can be shared directly from the slitting line’s PLC through industrial communication protocols like Ethernet or Profibus. This ensures real-time data exchange and seamless synchronization between cutting and packaging operations.

D. MES/ERP System Integration via API: Advanced lines can pull coil data directly from the company’s Manufacturing Execution System (MES) or Enterprise Resource Planning (ERP) systems via API. This real-time data sharing ensures that the correct coil dimensions are used without manual intervention, providing a high level of automation and precision.

2. Precise Sensors and Encoders for Coil Lifter Positioning

Accurate coil positioning is critical to ensuring that the downender’s lifter picks up only one coil at a time. This is achieved through the use of precise sensors and encoders that feed real-time positioning data into the PLC program of the packing line. The sensors detect the coil's exact position on the conveyor or turnstile, while the encoders monitor the lifter’s movements. The PLC uses this data to ensure that the lifter is correctly positioned for each coil’s width. This precision prevents the lifter from overlapping onto adjacent coils or missing the target coil, reducing errors and increasing operational efficiency.

3. Mechanical Lifter with Adjustable Extension and Shrinking Capabilities

The mechanical lifter of the downender is designed to adjust according to the width and weight of each coil. It is capable of extending and shrinking to match the maximum coil width specified in the system settings. Additionally, the lifter’s hydraulic-driven lifting capacity is calibrated to handle the maximum loading weight for each coil. By adjusting its size and strength per coil specifications, the lifter ensures that only one coil is picked up at a time, preventing damage or handling errors caused by excessive or uneven loading. This adaptability is key to maintaining the integrity of the packaging process, especially when handling coils of varying sizes and weights.

By the combination of accurate data input, real-time sensor feedback, and adjustable mechanical components ensures that the downender’s lifter picks up coils efficiently and without error. This prevents the simultaneous pick-up of multiple coils or the missing of coils altogether, leading to a smoother and more reliable packaging operation.

SPECIAL POINTS FOR THE COIL PACKING LINE:

Automating the process of coil weight measurement: This system accurately measures coils weighing between 500 kg and 2,000 kg. With dimensions varying from 1.2 m to 2.5 m in diameter, it ensures precision within ±1%. By automating weight checks, it minimizes human error, enhances operational efficiency, and ensures compliance with shipping standards.

Reducing packaging waste through optimized materials: The packing line utilizes eco-friendly materials with thickness ranging from 0.2 mm to 0.5 mm, enabling a reduction in waste by up to 30%. This innovation not only lowers costs but also promotes sustainability. The compact design allows for easy recycling, addressing environmental concerns effectively.

Enhancing safety during coil handling: Equipped with safety features including automatic shut-off and overload protection, the line can handle coils up to 3 m in length and 1,500 kg in weight. This reduces the risk of accidents during operations. Enhanced safety protocols lead to fewer workplace injuries, ultimately improving employee morale and productivity.