Improvement describe of Mastercoil wrapper packing machine

We provide the modification and upgrade service for Mastercoil wrappers for some customers. Since it’s too expensive to ask the service from a company that produces them, they come to us. And so we make a solution after checking and inspecting their equipment.
A. MasterCoil wrapping machine

 

B. Hydraulic system improvement of four coil trolleys

1. hydraulic system check of coil wrapping machine

Fault：No high pressure, low pressure action particularly slow；

On-site inspection：

After careful inspection, it is found that there are obvious scratches on the surface of the inner disk of the gear pump, indicating that there are hard impurities in the system to contaminate the high and low pressure control valve group and the reversing speed control valve group.

Reason：high-pressure pump damaged and pressure regulating cartridge valve stuck

Through the inspection of the damaged pump, it is found that there are obvious scratches inside. From this analysis, the reason for the damage of the pump may be caused by impurities entering the hydraulic system, causing internal components to wear, so that the internal leakage is too large to produce high pressure. The cartridge valve selected for the control and speed control valve group has poor anti-pollution ability to the oil, so the cartridge valve is damaged.

Solution：

（1）Replace the high and low pressure control valve group, the reversing speed control valve group, and use the plate valve with stronger pollution resistance；

（2）Install a filter on the low pressure return line

Because the hydraulic system requires relatively high oil cleanliness, once the system is contaminated, simply replacing the components cannot solve the root cause, and it may be damaged again. The oil tank and pipeline in the original system should be cleaned and the filter element should be replaced.。

2. Hydraulic system check of coil upender：

Fault：No high pressure, too slow turnover. Normally, it takes 60 seconds to turn the coil by 90 degrees, but now it takes 240 seconds. The efficiency is 1/4 of the original, which seriously affects the production capacity.

 

On-site inspection：

When the high and low pressure valve group is under low pressure, the pressure is 10MPa, and when the high pressure is switched, the pressure drops to 8MPa, and the sound is obviously abnormal, indicating that the high pressure pump is damaged.

Reason：Damaged high pressure pump；

Through the analysis of the principle, the pressure control valve of the high-flow pump is always under pressure. Each time the motor is energized, it will start under full load, so the impact on the motor and the pump is relatively large. If the working frequency is high, it will greatly affect the service life of the pump.

Solution：

（1）Replace the high and low pressure valve group, when the motor starts, set the pressure valve to the unloading state, and start without load；

（2）Install a filter on the high pressure return line

Clean the oil tank and pipeline in the original system, and replace the filter element.

1. When the trolley lifts aluminum coils of more than 20 tons, there is insufficient supply pressure at the risk of aluminum coils falling；

2. The service life of the pump of the trolley is short；

3. The double pump of the coil upender is damaged, the oil system is polluted, and the turning efficiency is extremely low.

3）PLC&HMI  server update：

1. Hardware: 2 sets of HP DL 160Gen 8, change into new models, original models discontinued;

2. Software: add the function of modifying/deleting coil information

PLC:

￭When the secondary server is not used, the packaging line can be wrapped normally.

￭It is necessary to add the function of coil information input on the HMI