HRZU3000B Automatic layer winding machine is the new generation of welding wire spooler without 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.
It can be running at highest line speed of 30m/s, the actual running speed is 25m/s.
In addition, several improvements have been supplemented to ensure safety, reliability, also to reduce labor intensity and the cost of production.
Equipment Composition:
- One HRZ3000B layer winding machine includes: Bobbin pay-off→ machine→Dancer→Main winding machine→Control cabinet
- Automatic plastic spool feeding machine.
- Centralized tray of spools feeding system(Optional)
- Automatic stacking system(Optional)
- Automatically print label and stick to spool (Optional)
Automation Performance
Plastic spool on feeding machine will be recognized and adjusted to correct facing automatically.
Empty spool can be picked up from feeding machine and clamped on winding machine by three-axis servo moving mechanism.
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 to stop. Three-axis moving mechanism intervenes to 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.
Human assistance required: Load/unload of bobbin, butt joint of welding wire, adjustment of straightener, load empty spool to feeding machine.
Main Specification
Motor: 7.5KW AC motor for main machine, drove by 7.5KW high performance frequency converter.
Wire specification:Φ1.0-2.0mm for flux-cored welding wire, Φ0.8-2.0mm 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).
Winding speed: 0-35m/s variable speed, the actual work speed is affected by wire diameter, the weight of each plastic spool, and linearity.
Wire spreading control method: Stepping motor numerical control.
Specification of plastic spool:
D270: Φ270×Φ150×90×Φ5mm (Max Dia.×Min Dia.×inner width×Shaft hole Dia.), 12-18kg/spool.
D300: Φ300×Φ200×90×Φ5mm (Max Dia.×Min Dia.×inner width×Shaft hole Dia.), 12-18kg/spool.
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.
Straightener: 2-dimension and 26 rollers in total, processed with 6200 bearing.
Bobbin outer diameter: Φ800mm, (Or customized on costumer’s demand).
Pay-off method: Active pay-off by 45KW AC motor with constant tension.
Air pressure: ≥5MPa.
Gross power: 54KW (Practical operating average power around≤10KW).
Area: 3000mm*6000mm.
Optional Parts
Centralized Tray of Spools Feeding System (optional)
According to the type of plastic spools required by each layer winding machine, the centralized spool supply system can prepare the spools in advance in the storage according to the required type.
The truss system will automatically transport the prepared spools to the automatic spool feeding machine of the corresponding layer winding machine.
The head of the truss system only needs sliding contact line for power supply. It has independent electrical control system and uses wireless communication with other parts of the equipment. It is unnecessary to drag cables and air hose accessory components.
According to the needs of the site, flexible configuration of the number of plastic spools bins and installation position.
Each plastic spool bin is divided into three layers and each layer can place at least 140 plastic spools.
Each layer has the function of detecting missing of spools and spools protection.
Automatic Stacking System (optional)
It is to grab and place the plastic spool full of welding wires on the trolley or storage and transportation device.
X, Y, Z movement of three coordinates.
It has the function of grabbing disc detection, which can detect whether the plastic disc with full wire is really caught. If it is not caught, it will automatically stop and alarm.
Servo motor, Servo controller and PLC are the products of Inovance.
Each automatic stacking machine can handle 4 pieces automatic layer winding machine. If an excess of spools accumulated in certain winding machine, then 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 or storage and transportation device (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.
The number of spools that can be placed on the trolley or storage and transportation device, can be designed according to user requirements.
