Automatic Layer Winding Machine HRZU3000
HRZU3000 Automatic layer winding machine is the new generation of welding wire spooler with mechanical arm system.
This set of equipment achieves a high level of automation in plastic spool feeding, loading/uploading of plastic spool, wire cutting, bending, ending and stacking processes etc.
This new generation of welding wire spooler can be running at highest line speed of 30m/s, the actual running speed is 25m/s.
Several improvements have been supplemented to ensure safety, reliability, also to reduce labor intensity and the cost of production.
Equipment Composition
- Two sets of HRZ3000 layer winding machine and each set includes: Bobbin pay-off→ machine→Dancer→Main winding machine→Control cabinet.
- One set of mechanical arm system (tool components for layer winding is included).
- One set of automatic plastic spool feeding machine.
- Automatic stacking system(optional).
Automation Performance
Plastic spool on feeding machine will be recognized and adjusted to correct facing automatically.
Mechanical arm picks up the spool and load to layer winding machine automatically.
Fully automated process of loading/unloading of plastic spool.
Fully automated process of wire bending for beginning and ending.
When the weight of wire wound on spool is approaching to preset wight, machine will slow down and stop, then mechanical arm intervenes and take care of cutting, bending and ending processes all in automatic manner.
After winding, automatically release the spool and roll out from winding machine.
If chaos occurs during winding, machine will automatically slow down to stop, winding backwards till no more chaotic wire on spool, then start winding forwards again.
Reserved communication port at user’s convenience for data collection and data manipulation.
Automatically print label and stick to spool (optional).
Human Assistance Required
Load/unload of bobbin, butt joint of welding wire, adjustment of straightener, load empty spool to feeding machine.
Main Specification
Wire Specification：
Φ1.0-1.6mm for flux cored welding wire, Φ0.8-1.6mm for solid welding wire (ovality of diameter of welding wire is less than 0.005, the diameter difference of welding wire in one spool is less than 0.005).
The winding speed is 0-30m/s, the actual work speed is affected by wire diameter and linearity.
Specifications of Plastic Spool:
Φ270×Φ150×90×Φ52.5 (Max diameter ×Min diameter ×inner width ×Shaft hole Dia.), the capacity of the spool is 15-20kg.
The bottom surface of the spool is grooved, the opening position must meet our drawing requirements. The diameter tolerance of welding wire must be compatible with the groove of spool.
Wire Spreading Control Method:
Preset track layout method can effectively determine the situation of tangled threads.
Straightener:
The horizontal direction of 1 group and the vertical direction of 1 group, each group has 13 killing rollers, total 26 rollers. The killing roller processed with 6200 bearing.
Power consumable:
The drive motor of take up machine is AC Servo motor (15KW), and the pay-off machine is AC motors (45KW). The power may be changed with the different bobbins.
Power supply:
3 phases 380V/50Hz, total 124KW (Practical operating average power around≤20KW).
Area:
5000mm ×6000mm (Width × length).
HRZ3000 Winding Machine
In order to adapt higher running speed, the winding machine frame is strengthened by following improvements:
Integrated machine frame with motor base, hence, main motor is placed outside of the machine frame with individual gas circuit cabinet.
Using 20mm welded steel plate in box-type structure with annealing.
The weight of main machine about 2000kg.
Improvements of bearings are implemented to improve the performance and life-time of bearings. In addition, the improved the belt drive system increases rotate speed and lower the noise in high speed operation.
The main motor is 15KW AC asynchronous motor, drove by 15KW frequency converter by ‘Inovance’ to adapt running speed of 30m/s.
Spreading Mechanism:
The junction plate on spreading mechanism is made of aluminum alloy and hollow sliding rod to lower the weight. When running speed of main shaft climbs to 4000 rpm, the speed of spreading will also increase by 50%, therefore, impact force is also much higher than before.
To deal with this problem, the original 26 rollers straightener are moved inside of the dancer, left with one dimension 9 rollers and a pound wheel on spreading mechanism to minimize the weight, thus, minimize the impact force while reversing
Protection shield is manually controlled for higher entirety safety purposes, the equipment can only run at low speed if it is not shut down.
Safety
Machine is equipped with emergency braking system, main winding machine and pay-off machine adopts cylinder wheel braking which allows emergency stop in case of chaos of wire fracture.
Emergency button on control panel, push to shut down the machine in case of emergency.
Winding machine is covered with a shield, when machine start operating, the shield will be closed simultaneously.
A reliable wire breakage detection device is designed to provide emergency shutdown in case of wire breakage.
Automatically alarm and stop when air pressure in cylinder is too low to prevent bobbin from falling.
In the case of sudden power lost (blackout), overall running speed will slowdown under full function of controlled while kinetic energy from bobbin will supply power to PLC by inverter.
The protection fence is available by the customer’s demand. Similar as protection shield cover on winding machine and operation will shut down automatically if the protection fence is open during operating.
Mechanical Arm System
Adopting a complete set of Inovance industrial robots, with extended arms and large load capacity.
The electromagnetic valve and cylinder on the robotic arm are products of AirTAG Taiwan.
Equipped with pneumatic clamps and scissors which can achieve fully automatic operation of welding wire layer winding, loading and unloading plastic discs, welding wire cutting, bending hooks, and ending binding processes.
Equipped with an external control box which can control robot operation, emergency stop, etc.
Separate control system and separate electrical control cabinet.
Communicate transmission signals with the layer winding machine PLC ensure that the execution sequence of each action is not disrupted.
Safety guardrails can be configured according to customer needs to ensure the safe operation of the equipment.
Automatic Plastic Feeding Machine
Unlike plastic spool used in tradition layer winding machine, in order to coordinate with automatic layer winding machine, plastic spool has to be grooved on inner core which result in the left side of plastic spool and right side of plastic spool are not symmetrical.
Normally the winding process starts at the left side of spool where a hole is predrilled for hook the wire. When the robot grabs the plastic plate it must grasp the right side of the plastic plate in order to install it correctly on the layer winding machine.
The operator only needs to neatly place the plastic disc in the hopper of the automatic disc feeder. The plastic disc can be placed in any direction without the need for manual identification of the direction of the plastic disc.
The automatic disc feeder can automatically recognize the side direction of the plastic disc and provide it in the correct direction for the robot to grasp.
AC Motor for feeding machine is product of ‘MAILI’ with power of 40W only.
High performance of variable-frequency drive for AC motor from ‘Inovance’
Sensors are the products of ‘Autonics’ buttons from ‘IDEC’
Adopted Siemens S7-200 SMART PLC for control program, and intercommunication with PLC used in winding machine.
Automatic Stacking System(optional)
X Y Z movement of three coordinates.
Built-in scale to check the weight of spools. In the case of weight of spool is not satisfied with standard weight, machine will stop and alarm.
Servo motor, Servo controller and PLC are the products of ‘Inovance’.
Each automatic stacking machine can handle three set of HRZU-3000 (6 winding machines). If an excess of spools accumulated in certain winding machine the stacking system will inform that winding machine to pause. The number of spools that will trigger the alarm can be set in touch screen.
Stacking system is able to learn the specification of transportation carts (memorize the location and height) to adapt with different working environment.
Wireless communication with PLC of winding machine operates in the demand order of each layer winding machine.
Push emergency button to shut down the machine in the case of emergency.
