Santrauka Automatic horizontal orbital bar wrapping machines spiral wrap continuous bundles of round, square, and hexagonal profiles as they pass through a high-speed rotating ring. An integrated pneumatic clamp-and-cut mechanism automatically secures, indexes, and severs stretch film at bundle transitions, enabling fully unattended inline finishing. Because structural metal alloys possess high volumetric mass density (~7,850 kg/m³ for steel, ~2,700 kg/m³ for aluminum), dynamic conveyor bearing ratings limit equipment payload long before bundle dimensions fill the ring aperture.8 kg; a standard 100 kg payload wrapper reaches its structural threshold with just 6 bars**, regardless of residual ring clearance.
Kaip mašina suvynioja strypo ryšulį
In automated bar mills, cold-drawing lines, and profile distribution centers, the horizontal orbital stretch wrapper integrates directly into powered roller handling lines. Metal bundles feed horizontally through the rotating ring axis, eliminating overhead crane staging or manual secondary strapping. The wrapping sequence follows four synchronized operations:
- Infeed and Indexing: Powered V-groove or flat conveyor rollers transfer the rigid bundle into the wrapping station. Heavy-duty retro-reflective photocells detect the bundle front end to trigger wrapping cycles.
- Orbitinis spiralinis apvyniojimas: A balanced rotating ring guides the film carriage circumferentially around the workpiece while motorized conveyors control linear transit. This synchronized motion applies a continuous, tight helical protective layer.
- Pneumatinis pjovimas ir spaustukas: At the bundle tail end, a pneumatic scissor-blade mechanism severs the film web while an automated mechanical gripper secures the film tail for seamless introduction onto the next incoming package.
- Išleidimo anga: Motorized outfeed conveyors transfer the wrapped bundle to downstream staging racks, accumulation tables, or strapping equipment.
Dual variable-frequency drives (VFD) regulate ring angular rotation and conveyor linear travel independently. Packaging film overlap is fully adjustable between 10% and 90% via the HMI operator interface, governed by the kinematic formula:
Overlap % = [1 - (V_conveyor / (N_ring × W_film))] × 100%
kur:
V_conveyor= Linijinis linijos greitis (m/min)N_ring= Orbitinio žiedo sukimosi greitis (aps./min.)W_film= Efektyvus plėvelės juostos plotis (m)
Kodėl svoris lemia modelį
Selecting an orbital wrapper requires evaluating both geometric envelope (usable ring diameter) and dynamic structural payload (roller bearings, chassis deflection limits, and drive motors). For dense metal bundles, structural limits are reached well before exhausting the physical aperture.
The nominal linear mass of solid round metal bars is calculated from material density and cross-sectional area:
Linear mass (kg/m) = ρ × (π / 4) × d²
kur:
ρ= Material density (Carbon/Alloy Steel ≈ 7,850 kg/m³; Aluminum Alloys ≈ 2,700 kg/m³)d= Strypo skersmuo (m)
Reference mass values for standard stock sizes:
- Ø20 mm solid steel bar: Skerspjūvio plotas = 0.000314 m²; linijinė masė = 2.47 kg / m. A standard 6 m bar weighs 14.8 kg.
- Ø12 mm solid steel bar: Skerspjūvio plotas = 0.000113 m²; linijinė masė = 0.89 kg / m. A standard 6 m bar weighs 5.3 kg.
- Ø20 mm solid aluminum bar: Skerspjūvio plotas = 0.000314 m²; linijinė masė = 0.85 kg / m. A standard 6 m bar weighs 5.1 kg.
Bars per bundle: Geometric sizing and payload verification
Determining how many bars fit into a stable bundle requires a two-step validation: cross-sectional geometric packing and total payload verification.
[ Bar Diameter (d) ] ↓ [ Hexagonal Packing Approximation ] → Bundle OD ≈ d × [1 + √3 × (n_layers – 1)] ↓ [ Calculate Total Mass (m_total) ] → m_total = n_bars × Unit Weight ↓ [ Payload Gate Check ] → Is m_total ≤ 100 kg (E300/E400) or ≤ 200 kg (E600)?
1. Geometric Bar Count Solving
When round bars are stacked in a nested hexagonal configuration, bundle outer envelope diameter (OD_bundle) relates to the individual bar diameter (d_bar) and concentric stacking layers (n_layers):
OD_bundle ≈ d_bar × [1 + √3 × (n_layers - 1)]
For a tight cluster where individual bars n fit inside a target circular diameter:
- Dėl Ø20 mm bars inside a target 100 mm bundle envelope:
n ≈ 4 to 5 bars(A 4-bar diamond or 5-bar clustered geometry yields an outer boundary of ~60–85 mm). - A 7-bar concentric hexagon (1 center + 6 outer) yields:
OD_bundle ≈ 20 × (1 + 1.732 × 1) ≈ 54.6 mmenvelope diameter.
2. Structural Mass Gate Check
Once the bar count n is established geometrically, total bundle mass (m_total = n × unit weight) determines machine compatibility:
| Strypo skersmuo | Unit Weight (6 m Steel) | Maksimalus skaičius (100 kg riba) | Maksimalus skaičius (200 kg riba) |
|---|---|---|---|
| Ø12 mm | ~ 5.3 kg | 18 barai (apie 53 770 kg) | 37 barai (apie 53 770 kg) |
| Ø20 mm | ~ 14.8 kg | 6 barai (apie 53 770 kg) | 13 barai (apie 53 770 kg) |
„Sunki, bet plona“ inžinerijos dilema
Thirteen Ø20 mm bars in a cluster weigh ~192.4 kg and need an E600, yet the cluster is only 80–100 mm OD — far below the E600’s 200–600 mm working envelope.
This lower boundary is governed by tooling mechanics:
- Cilindro eigos ribos: Standard overhead vertical hold-down pneumatic cylinders bottom out before contacting bundles under 200 mm OD, leading to bundle shifting under rotational film tension.
- Konvejerio tilto tarpai: The central gap between infeed and outfeed roller conveyors causes narrow, heavy bundles to sag under deadweight.
To process slim, heavy profiles safely, our engineering designs incorporate extended-stroke hold-down cylinders and lagged intermediate bridge rollers across the ring throat, specified per project.
Model windows and cycle time estimation
Model selection follows unambiguous structural and dimensional boundaries:
- E300 Threshold: Bundle OD ≤ 300 mm and total bundle weight ≤ 100 kg.
- E400 Threshold: Bundle OD between 300 mm and 400 mm with total bundle weight ≤ 100 kg.
- E600 Heavy-Duty Escalation: Mandatory whenever bundle weight exceeds 100 kg (rated to 200 kg) OR bundle OD exceeds 400 mm (rated to 600 mm).
| Mašinos modelis | Bundle OD Envelope | Dynamic Load Limit | Ruošinio ilgis | Skambėjimo greitis | Linijinio vyniojimo greitis | Įdiegta galia |
|---|---|---|---|---|---|---|
| E300 | 100 – 300 mm | 15-100 kg | ≥ 1,000 mm | 20–90 aps./min | 5-15 m/min | ~2.5 kW (380V 3ph 60Hz) |
| E400 | 100 – 400 mm | 15-100 kg | ≥ 1,200 mm | 20–90 aps./min | 5-25 m/min | ~2.5 kW |
| E600 | 200 – 600 mm | 20-200 kg | ≥ 800 mm | Reguliuojamas | Conveyor: 3–12 m/min | ~4.5 kW (380V 3ph 50Hz) |
Packaging Tact Time Calculation
Linear line speed (v) and bundle length (L) govern continuous packaging cycle time (t), estimated by:
t = L / v
(The formula assumes constant-speed wrapping; acceleration, deceleration and the clamp/cut actions add time per cycle, so measure the actual cycle on the line before quoting a throughput figure.)
- On the E300 (5–15 m/min line speed): Wrapping a standard 6 m bar bundle takes 24 iki 72 sek.
- On the E400 (5–25 m/min line speed): Wrapping a standard 6 m bar bundle takes 14.4 iki 72 sek.
- On the E600 (3–12 m/min conveyor speed): Traversing a 6 m bundle takes 30 iki 120 sek.
Bepilotis plėvelės pjovimas ir tiekimas
The automatic clamping, feeding, and cutting unit eliminates manual handling during active wrapping cycles:
- Automatinis prispaudimas ir padavimas: At cycle start, an internal pneumatic clamp positions the film tail into the ring path. Forward bundle travel traps the film web against the material, and the gripper releases automatically once helical tension stabilizes.
- Tikslus pneumatinis pjovimas: Once the preset wrap count is completed at the trailing edge, a double-acting pneumatic cylinder drives an industrial serrated blade to sever the film web cleanly.
- Pradinės pozicijos indeksavimas: A proximity sensor and motor dynamic brake lock the orbital ring at its precise zero-point datum after cycle completion, ensuring proper mechanical alignment for the next feed cycle.
- Sistemos stebėjimas: The integrated PLC tracks film breakage, roll exhaustion, pneumatic pressure drops, and photocell blockages, displaying system status on stack lights and the touchscreen HMI.
Komunalinės paslaugos ir saugumas
| Utility / Parameter | E300 System | E400 Multi-Material System | E600 sunkiųjų transporto priemonių sistema |
|---|---|---|---|
| Elektros tiekimas | 380V, 3-Phase, 60 Hz (~2.5 kW) | 380V, 3-Phase, 50/60 Hz (~2.5 kW) | 380V, 3-Phase, 50 Hz (~4.5 kW) |
| Suspaustas oras | 0.5–0.8 MPa (5–8 kgf/cm²), dry | 0.5–0.8 MPa (5–8 kgf/cm²), dry | 0.5–0.8 MPa (5–8 kgf/cm²), dry |
| Palaikomos pakavimo laikmenos | PE film (OD 100–200 mm, Width 100–200 mm, ID 50 mm) | PE, Paper, PP, Woven tape (OD 100–200 mm, Width 100–200 mm, ID 50/76 mm) | LLDPE, Paper, Woven tape (OD 100–250 mm, Width 150–300 mm, ID 50 mm) |
| Conveyor Bed Configuration | Infeed & Outfeed: 2,000 mm each; Speed: 6–12 m/min | Infeed & Outfeed: 2,000 mm each; Speed: 6–12 m/min | Infeed & Outfeed: 2,000 × 800 mm; Speed: 3–12 m/min |
| Mašinos matmenys | Standard inline modular layout | Standard inline modular layout | Apytiksliai ilgis 5,200 × plotis 1,800 × aukštis 1,800 mm |
Pramoninės saugos atitiktis
- ISO 12100: 2010: Comprehensive machinery safety risk assessment and hazard elimination.
- EN 415-10:2014: Standardized safety requirements for automated packaging and wrapping machines.
Atrankos kontrolinis sąrašas
When specifying an orbital bar wrapping configuration, supply the following parameters:
- Material profile and grade (round bar, hex rod, square stock, hollow tube; steel or aluminum).
- Individual bar dimensions: Cross-section / OD (mm), standard cut length (mm), and unit mass (kg).
- Target bundle configuration: Total bar count per bundle and total bundle weight (kg).
- Bundle envelope dimension: Measured minimum and maximum diagonal envelope (
OD_bundle, mm). - Packaging medium: LLDPE film, VCI anti-corrosion film, crepe paper, or reinforced woven polypropylene.
- Line speed requirement: Target bundles per hour and available upstream cycle time.
- Integration mode: Standalone packaging cell with manual feeding vs fully automated inline roller integration.
Inžinerijos DUK
Q: How do you calculate the weight of a solid 6 m, Ø20 mm steel bar?
A: Linear mass is calculated as 7,850 kg/m³ × [π × (0.010 m)²] = 2.466 kg/m. Multiplying by 6 m yields 14.80 kg.
Q: Why does a 100 kg rated wrapper only take 6 pieces of 6 m, Ø20 mm steel bars? A: Each 6 m bar weighs 14.8 kg. Six bars total 88.8 kg, safely under the 100 kg frame rating. Adding a seventh bar brings total weight to 103.6 kg, exceeding conveyor bearings and structural drive design limits. Bundles of 7 to 13 bars require an E600 system (up to 200 kg).
Q: Why cannot a standard E600 clamp an 80 mm OD steel bundle despite its 192 kg mass? A: Standard E600 tooling is optimized for 200–600 mm OD profiles. On an 80 mm bundle, vertical hold-down pneumatic cylinders reach maximum stroke without applying adequate clamping force, allowing bundles to rotate under film tension. Sizing this application requires engineered long-stroke cylinders and center bridge rollers.
Kitas žingsnis
Our mechanical design group configures custom bar handling and orbital wrapping systems:
- Pateikite proceso duomenis: Send material profiles, bundle packing drawings, and plant layout drawings to our application engineering team.
- Technical Quotation within 24–48 Hours: Receive a detailed proposal including ring sizing calculations, overlap kinematics, payload ratings, and dimensional footprints.
- Engineering Integration Review: Confirm conveyor height matching, VFD synchronization, safety interlocking, and PLC handshakes.
Šaltiniai
- Fhopepack product pages: E300, E400, E600 horizontal orbital stretch wrappers.
- ISO 12100:2010 — Safety of machinery: general principles for design, risk assessment and risk reduction.
- EN 415-10:2014 — Safety of packaging machines: general requirements.
Paskutinį kartą peržiūrėta: 2026-11-05
