آلة تعبئة المحامل الأوتوماتيكية للمحامل الكبيرة: تحديد الحجم، والتداخل، ووقت التغليف

ملخص تنفيذي The FPB series industrial bearing packing machine automates the orbital wrapping of heavy-duty slewing, roller, and spherical bearings positioned horizontally (eye-to-sky) on powered conveyors. By shuttling stretch film, VCI anti-corrosion film, or woven knit belts through the inner bore via a vertical rotating ring, the machine applies tensioned helical wraps around the complete annular cross-section. The FPB-400 processes outer diameters (OD) of 500 – 1,200 مم, bore inner diameters (ID) down to 300 mm, and package loads up to 500 kg within 30-50 ثانية per unit. Selection is engineered directly from bearing core dimensions, face width, and line integration requirements.

جدول المحتويات

كيف يعمل غلاف المحمل

The wrapping sequence begins when the infeed powered roller conveyor transfers the bearing horizontally into the central wrapping station. A pneumatic centering roller assembly clamps and aligns the bearing to the exact orbital center of the rotating shuttle ring.

Once aligned, the vertical shuttle ring carries the film reel through the open inner diameter (bore) of the bearing. Simultaneously, powered support rollers rotate the bearing horizontally about its vertical central axis. This orthogonal dual-axis movement creates a continuous helical wrap enclosing the bearing’s outer diameter, inner raceway, and both side faces.

Integrated optical sensors track cycle progress, decelerate the inverter-driven ring at home position, and initiate an automatic pneumatic clamp-and-cut system to sever the material tail. The completed bearing is then discharged to the outfeed gravity or driven conveyor line.

خط تعبئة محامل أوتوماتيكي مزود بآلة تغليف حلقية، وسيور ناقلة أسطوانية، ولوحة تحكم.
خط تعبئة المحامل الأوتوماتيكي. تقوم ناقلات البكرات بتغذية المحامل إلى آلة لف الحلقات.

FPB-300 أو FPB-400

المعايير الهندسية FPB-300 FPB-400
Bearing outer diameter (OD) 600 – 1,200 مم 500 – 1,200 مم
Bearing inner diameter (ID) 300 – 900 مم 300 – 800 مم
Bearing width (face height) 20 – 300 مم 100 – 400 مم
Maximum payload weight 10-500 كجم 100-500 كجم
سرعة دوران الحلقة 30–70 دورة/دقيقة 30–70 دورة/دقيقة
Unit wrap cycle time 40-50 ثانية لكل محمل 30-50 ثانية لكل محمل
Film overlap range قابل للتعديل بنسبة 20-80% قابل للتعديل بنسبة 20-90%

Selection depends primarily on bearing face width and bore clearance:

  • Bearings with a face width between 300 mm and 400 mm require the extended clearance envelope of the FPB-400.
  • Narrow bearings with a face width under 100 mm (down to 20 mm) require the closer roller pitch of the FPB-300.
  • Large bearings with an inner bore exceeding 800 mm (up to 900 mm) must be routed to the FPB-300 to ensure proper radial clearance for the film dispensing carriage.

التداخل عند القطر الخارجي

Because circumference increases with radius, the film overlap is lowest at the outer diameter (OD) and tightest at the inner bore (ID). To prevent moisture entry and dust ingress, packaging tension and conveyor feed speed are calibrated to guarantee the specified minimum overlap at the maximum OD.

The allowable wrap count within a targeted cycle time depends directly on ring RPM:

  • Maximum wraps available at 70 r/min in a 50 s cycle: (70 r/min ÷ 60 s) × 50 s ≈ 58 wraps.

Calculated overlap for a 1,000 mm OD bearing استخدام 100 mm width packaging material:

Targeted Overlap at OD Advance per Wrap Required Wrap Count Wrapping Time at 70 r/min
50% سماكة 50 ملم π × 1,000 mm ÷ 50 mm ≈ 63 wraps حوالي 54 ثانية
30% سماكة 70 ملم π × 1,000 mm ÷ 70 mm ≈ 45 wraps حوالي 38 ثانية

At a 50% overlap target, wrapping a 1,000 mm OD bearing requires 54 s of pure rotation, exceeding standard 50 s cycle targets. To operate within a 50 s cycle, set the OD overlap target to ≤ 46%, or switch to a 120–150 mm wide film roll to increase surface coverage per revolution.

عدد المحامل لكل وردية

Throughput calculations consider net wrapping cycle duration alongside material index, centering, and conveying index times.

Cycle calculation model based on a 38 s wrapping cycle (30% overlap on 1,000 mm OD):

خطوة الإنتاج Duration / Metric Value
Infeed conveying, pneumatic centering, clamping 12 ق
Helical orbital wrapping cycle 38 ق
Film cut, clamp, and outfeed index 8 ق
Total cycle time per bearing 58 ق
Practical output per hour (85% line OEE) about 52–55 bearings
Maximum theoretical output per 8 h shift محامل 496

Net shift yield will vary with roll change intervals and inline inspection delays. Both models integrate with upstream grinding/washing lines and downstream palletizing cells via standard clean dry contacts or fieldbus interfaces.

الإعدادات والبرامج

The FPB series utilizes an industrial PLC architecture paired with variable frequency drives (VFD) for independent control of ring rotation speed and roller turning speed. Operators input key bearing dimensions directly through the interface:

ميزة التحكم FPB-300 FPB-400
نظام التحكم Siemens/Delta PLC with Touchscreen HMI PLC with digital operator keypad
إدارة الوصفة إدخال المعلمات يدويًا Up to 6 pre-configured dimensional recipes
نظام تحديد المواقع Multi-sensor optical detection Automatic self-centering clamp arms
تنظيم السرعة Dual VFDs for ring and conveyor rollers Dual VFDs for synchronous ratio tracking
تشخيص الإنذارات Multi-tier beacon with HMI fault log Three-color tower light with audible buzzer

Preset recipes store rotational speed ratios, target overlap percentages, and pre-stretch tension settings, reducing changeover downtime to under 30 seconds when switching bearing product lines.

المواد

The ring carriage supports standard commercial industrial packaging media mounted on quick-release mechanical friction brake arbors:

  • VCI Anti-rust stretch film (20–35 µm): Blocks atmospheric humidity and emits protective corrosion-inhibiting vapor.
  • Crepe paper (Goffered paper, 70–120 GSM): Delivers structural cushion and oil absorption for heavy roller assemblies.
  • Woven PE/PP knit belt: Protects high-precision ground raceways against mechanical handling impacts.
  • PVC protective tape: Provides tight moisture-barrier outer wrapping.

Film tension is adjusted mechanically at the roll holder core to maintain elongation without tearing across sharp outer chamfers. The pneumatic tail cutter handles both stretch films and reinforced woven tapes.

المرافق والسلامة

Utility / Requirement FPB-300 FPB-400
الخدمة الكهربائية AC 380 V, 50/60 Hz, 3-Phase (Customized on request) AC 380 V, 50/60 Hz, 3-Phase (Customized on request)
قوة متصلة 2.5 كيلو واط 2.5 كيلو واط
توريد هوائي 0.5–0.7 MPa clean, dry compressed air 0.5–0.7 MPa clean, dry compressed air

Machine design complies with international industrial safety and machinery directives:

  • ISO 12100: 2010: Standardized risk assessment and risk reduction methodology.
  • EN 415-10: 2014: Safety requirements for packaging machines and integrated horizontal ring orbital wrappers.
  • Interlocked physical perimeter fencing, optoelectronic light curtains at conveyor infeed/outfeed ports, and Cat-3 emergency stop integration.

قائمة التحقق من اختيار غلاف المحمل

  • Outer diameter (OD), inner bore diameter (ID), and cross-section face width range.
  • Maximum bearing weight and surface finish condition (bearing dry or oiled).
  • Wrapping media combination (single-layer stretch film, VCI paper, or dual-material composite wrap).
  • Required minimum film overlap percentage at maximum OD.
  • Target cycle time and bearings-per-hour output demand.
  • Conveyor working passline height and line integration protocol (EtherNet/IP, PROFINET, or dry contacts).

أسئلة وأجوبة هندسية

Q: What are the exact dimensional limits for the FPB-400? A: The FPB-400 accommodates bearing outer diameters from 500 mm to 1,200 mm, inner bore diameters from 300 mm to 800 mm, face widths from 100 mm to 400 mm, and total payload weights from 100 kg to 500 kg.

Q: What conditions dictate selecting the FPB-300 instead of the FPB-400? A: Select the FPB-300 when handling thinner bearings with face widths between 20 mm and 100 mm, or when wrapping wide-bore bearings with inner diameters up to 900 mm.

Q: What is the typical wrapping cycle duration per unit? A: Cycle times range from 30 s to 50 s on the FPB-400 and 40 s to 50 s on the FPB-300, depending on selected rotation speed and OD overlap requirements.

Q: How are dimensional presets handled during shift changeovers? A: The FPB-400 stores up to 6 pre-configured product recipes inside the PLC memory. Selecting the program sets speed ratios, centering offsets, and overlap values instantly.

Q: Can the machine wrap with VCI paper and stretch film simultaneously? A: Yes, dual-dispensing ring carriages are optionally available to apply an inner VCI anti-corrosion barrier and an outer mechanical stretch film seal during a single cycle.

الخطوة التالية

Implement automated bearing wrapping in three streamlined phases:

  1. Submit your dimensional data sheet: Email your range of bearing OD, ID, face widths, unit weights, and target shift capacity to info@fhopepack.com.
  2. Review your formal technical proposal: Receive an engineered sizing assessment within 48 hours, covering roller spacing, ring clearance models, and conveyor layout drawings.
  3. Line integration & FAT: Confirm plant layout clearances, electrical interlocks, and scheduled Factory Acceptance Testing.

مصادر

آخر مراجعة: 2026-10-04

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