Ruļļu iepakošanas mašīnas iesaiņošana un apstrāde: iekraušanas iespējas

Name: Tērauda ruļļu iepakošanas mašīnas izvēle: apstrādes sistēmas, ruļļu logi un cikla laiks
Uploaded: 2022-03-07T07:23:06+00:00
Duration: 1 min 46 s
Description: > **Kopsavilkums** > Ruļļu iepakošanas iekārtu izvēlas tikpat daudz pēc ruļļa ievietošanas un izņemšanas veida, cik pēc tā izmēra. Mūsu klāsts aptver četras iekraušanas konfigurācijas, sākot no ruļļa ierullēšanas un nolaišanas no augšas ar celtni līdz iekraušanai ar ratiņiem un automatizētai pozicionēšanai. Ruļļa svars…

Kopsavilkums Ruļļu iepakošanas iekārtu izvēlas tikpat daudz pēc tā, kā ruļļi tiek ievietoti un izņemti, kā pēc to izmēra. Mūsu klāsts aptver četras iekraušanas konfigurācijas, sākot no ruļļa ierullēšanas un nolaišanas no augšas ar celtni līdz iekraušanai ar ratiņiem un automatizētai pozicionēšanai. Ruļļa svars svārstās no 20 kg ekonomiskajam modelim līdz 4,500 kg FPS-800, un iekraušanas metodei ir jāatbilst jūsu jau izmantotajiem celtņiem un iekrāvējiem.

Šūnu izkārtojums un apstrāde

In a modern steel processing installation, the coil wrapper operates inside a fully interlocked safety enclosure. The coil rests in an eye-horizontal orientation on a dual V-saddle equipped with heavy-duty drive rollers. Wrapping occurs as the high-speed orbital ring rotates through the internal bore (eye) of the coil while the powered support rollers slowly rotate the coil along its central axis, achieving full radial and circumferential film coverage.

       [ Orbital Wrapping Ring ]
               │       │
         ┌─────┼───────┼─────┐
         │     ▼ (Eye) ▼     │  <-- Ring rotates through coil eye
         │   ┌───────────┐   │
         │   │ SteelCoil │   │
         │   └───────────┘   │
         └─────────┬─────────┘
             ▲           ▲
        [PU Roller] [PU Roller] <-- Driven rollers rotate coil body

The V-saddle serves as the primary material handling interface. To eliminate plant crane wait times, industrial layouts often utilize a dual-saddle transfer shuttle: while one coil undergoes automatic wrapping, the staging saddle holds a finished package ready for off-loading. Matching the wrapper’s saddle design to your facility’s crane, C-hook, or walking beam minimizes crane dependency and maximizes overall equipment effectiveness (OEE).

Izturīga vertikāla tērauda ruļļu iesaiņošanas mašīna ar augšējo atvēršanas gredzenu lielu ruļļu iekraušanai ar celtni — **Izturīgs vertikālais ruļļu ietinējs FPS-400.** Augšējā atvere iekraušanai ar celtni vai iekrāvēju.

Četras iekraušanas konfigurācijas

The loading method directly determines cell cycle efficiency, structural footprint, and line automation levels:

Iekraušanas metode	Modeļi	Labākais, lai
Ierullējieties un izrullējiet	Ekonomiskais modelis	Light coils, low volume manual lines
Celtnis vai iekrāvējs no augšas	SPF-400	Heavy, large-OD coils in constrained floor space
Ratiņi, iekrauti ar celtni vai C veida āķi	SPF-500	Automatic cycles with integrated cut-and-clamp
Automatizēta pozicionēšana, papildu automātiska griešana un padeve	SPF-800	Continuous high-tonnage slitting and packaging lines

Floor-level roll-in/out (Economic): Designed for manual or light-crane operations where coils roll across a low-profile incline directly into the cradle. Suitable for light, non-critical strip coils.
Top-opening frame (FPS-400): The upper structural arch opens via pneumatic or electromechanical actuation, allowing an overhead shop crane or mast forklift to lower coils vertically into the saddle without end-clearance interference.
Automated trolley shuttles (FPS-500): Coils are deposited onto an external transfer cart outside the safety fence. The motorized cart translates into the wrapping zone, decoupling factory crane dispatch from the packaging cycle.
Powered inline positioning (FPS-800): Incorporates bidirectional motorized roller tables and centering stations to align heavy coils automatically, supporting unattended continuous packing cells.

Spoles tipa logi pēc modeļa

Selecting the correct model requires confirming that your minimum and maximum coil dimensions fit within the ring cross-section and roller center distances:

Parametrs	Ekonomiskā	SPF-400	SPF-500	SPF-800
Spoles ID diapazons	508–610 mm	508 vai 610 mm	508 vai 610 mm	400–950 mm
Spoles ārējā diametra diapazons	600–1,200 mm	800–1,400 mm	700–1,400 mm	700–1,600 mm
Spoles platuma diapazons	100–300 mm	100–400 mm	200–500 mm	400–850 mm
Spoles svara izturība	20-1,000 kg	100-2,000 kg	80-1,000 kg	500-4,500 kg
Piedziņas jauda	1.5 kW	4.0 kW	2.0 kW	Project specific (approx. 5.5–11 kW)

Engineering sizing rule: The ring internal diameter (ID_ring) must satisfy the geometric envelope of the coil cross-section: ID_ring ≥ √[ (OD - ID)² / 4 + Width² ] + C kur C ≥ 250 mm represents the physical clearance required for the rotating film carriage and pre-stretch delivery head.

Selection example: A 1,500 kg slit coil with 610 mm ID, 1,300 mm OD, and 350 mm width matches the FPS-400 top-loading envelope. A 3,500 kg master coil with a width of 600 mm requires the structural capacity and drive torque of the FPS-800.

Cikla laiks un izvade

Nominal wrapping time differs significantly from operational floor capacity due to loading and unloading overhead:

Modeļi	Tīrs ietīšanas cikls	Theoretical maximum	Real-world line output (with crane/forklift)
SPF-500	20–45 s uz spoli	80–180 coils/hour (3,600 ÷ T_wrap)	25–45 coils/hour (limited by handling)
SPF-800	45–90 s uz spoli	40-80 spoles stundā	20–45 coils/hour (integrated automation)

Total cycle time per coil is calculated as: T_total = T_load + T_wrap + T_clamp_cut + T_unload

While the orbital ring can complete wrapping in 30 seconds, factory cranes serving multiple production stations typically introduce a 60–120 second transit delay per coil. Integrating an automated shuttle trolley or powered staging saddle mitigates this delay by allowing parallel staging of downstream coils.

Spoles virsmas aizsardzība

Preventing mechanical marking, friction burns, and atmospheric corrosion during wrapping is critical for high-value cold-rolled, galvanized, and stainless steel:

Polyurethane (PU) roller lining: Roller bodies on the FPS-400 and FPS-800 are vulcanized with high-durometer PU (Shore A 90–95). This prevents metal-to-metal contact, eliminating surface scratches, roller-slip scuffs, and edge-creasing.
Packaging consumables: Compatible with LLDPE stretch film, VCI anti-corrosion film, neutral crepe paper, woven HDPE tape, and PVC protective films.
Dual-material synchronous wrapping: The FPS-400, FPS-500, and FPS-800 support dual-dispenser toolposts to apply two layers simultaneously in a single pass (for example: internal VCI film for corrosion inhibition plus external woven film for mechanical puncture resistance).
Programmable overlap ratio: Electronic ring and roller VFDs allow overlap ratios to be precisely adjusted between 10% and 90% via the HMI screen, maintaining moisture-proof integrity across narrow slit coils and wide coils alike.

Komunālie pakalpojumi un drošība

Parameter / Utility	Tehniskā prasība
Elektroapgāde	380 V (±10%), 50 Hz, 3-Phase + PE (FPS-800 supports 415 V / 480 V, 50/60 Hz)
Pneimatiskā padeve	0.4–0.6 MPa (4–6 bar), dry and filtered instrument air
Stretch film core dimensions	ID 50 mm / 76 mm; Film roll OD 100–450 mm; Width 100–150 mm
Trokšņa līmenis	≤ 78 dB(A) at 1.0 m operating perimeter

All automated wrappers conform to international machinery standards. Machinery intended for CE markets is designed and evaluated under:

ISO 12100: 2010: Mašīnu drošība — Vispārīgie projektēšanas, riska novērtēšanas un riska samazināšanas principi.
EN 415-10:2014: Iepakošanas mašīnu drošība — Vispārīgās prasības.
Standard physical interlocks include heavy-duty perimeter fencing, Category 4 optical safety light curtains at the loading portal, keyed LOTO disconnect switches, and fail-safe electromagnetic ring brakes.

Ruļļu iepakošanas un apstrādes izvēles kontrolsaraksts

Coil dimensional envelope: Confirm Minimum and Maximum ID, OD, Width, and Weight.
Handling logistics: Overhead crane, C-hook, counterbalanced forklift, walking beam, or coil car.
Throughput targets: Target coils per hour and crane utilization rates across adjacent lines.
Protection package: Single-material wrap vs. dual-layer wrapping (VCI + woven/stretch film).
Virsmas jutība: Mill finish, mirror polish, painted, or oiled surfaces requiring custom PU roller profiles.
Floor integration: Footprint limitations, safety fencing layout, and interlock zoning.

Inženierijas bieži uzdotie jautājumi

Q: Which wrapping model is optimal for overhead crane loading? A: The FPS-400. Its top-opening frame structure allows shop cranes and C-hooks to lower coils directly into the support saddle from above without horizontal clearance restrictions, handling coils up to 2,000 kg and 1,400 mm OD.

Q: What is the most cost-effective option for low-volume light coils? A: The Economic model. Coils between 20 kg and 1,000 kg roll in and out on floor-level ramps, making it ideal for decentralized batch processing or secondary slitting lines.

Q: How is the realistic throughput of the FPS-500 calculated? A: Although the wrapping ring completes its cycle in 20–45 seconds (giving a theoretical speed of 80–180 coils/hour), actual plant output averages 25–45 coils/hour due to manual or crane-dependent loading and unloading times.

Q: Can we apply corrosion inhibitor (VCI) and stretch film in a single operation? A: Yes. The FPS-400, FPS-500, and FPS-800 can be fitted with synchronized dual-reel dispensers to apply inner VCI paper/film and outer protective stretch film simultaneously.

Q: How are master coils exceeding 2,000 kg accommodated? A: The FPS-800 is engineered specifically for heavy duty cycles, handling coil weights from 500 kg up to 4,500 kg (with custom frames configurable up to 10,000 kg) using reinforced drive assemblies and powered positioning rollers.

Nākamais solis

To configure an optimized coil packaging station for your facility:

Submit your coil matrix: Send minimum/maximum coil dimensions, weights, and current plant handling layout to info@fhopepack.com.
Receive engineering proposal within 48 hours: Obtain an integrated layout drawing, model specification, cycle-time simulation, and utility requirement matrix.
Site survey & technical sign-off: Finalize mechanical safety interlocks, crane pick zones, and integration details with our engineering team.