Kohler Long Part Production Lines coiler and straightener

Kohler Long Part Production Lines coiler and straightener 

Long Part Production Lines Production of long parts The narrow strip is pulled by a braked coiler and straightened by a 21-roller precision leveling machine. To remove the existing camber resulting from coiling, the strip is also straightened vertically. This involves using a high-edge straightener. The strip is guided through rows of polished or profiled rollers at the inlet of the leveling machine and through transversely movable roller pairs at the outlet to counteract the camber.

Following the straightening, the material is precisely fed to the press either through looping or by using a high-dynamic roller feed via a strip loop. Finished parts are accelerated by a driver after punching to match the speed of the subsequent leveling machine. These parts, deformed by the punching process, are re-leveled by a roller leveling machine. The use of an integrated dampening chute at the outlet of the 9-roller leveler allows the deceleration of parts and their collection in transport containers.

This process can achieve strip speeds of up to 180 m/min. and a maximum output of 90 parts/min.

The configuration of these standard lines can be adjusted or enhanced. Long part production lines can be designed as single or double track setups, optimizing press capacity. Alternatively, transfer systems can allow parts to be transported inside the press transversely to the production direction.

Furthermore, our production program includes lines for limited lot production, flexible punching, and combinations of profiling, punching, folding, and bending.

Levelling Technology in Detail

Quick Change Device KOHLER has developed a quick change device for leveling and supporting rollers, primarily designed for cleaning the machine. This device facilitates easy and regular cleaning by maintenance personnel. Depending on machine size, roller frames can be extracted manually using a suitable tool and handwheel or hydraulically. This innovation significantly reduces maintenance time for roller changes.

Intermediate Rollers with Spiral Groove In cases where support roller marks on leveled material are undesirable, the leveling machine is equipped with intermediate rollers with spiral grooves. These rollers not only assist in leveling but also in cleaning the leveling rollers.

Roller Bending Device Roller bending devices are used to eliminate or correct transverse buckles, edge, or center waves. If the strip has significant rolling defects, stretcher leveling is required to bring it to a normal processing state. Two variants are available:

Roller bending en bloc creates an ideal bending line by adjusting the height of all support roller blocks.

Alternatively, the bending line can be adjusted individually using independently height-adjustable support roller blocks.

Roller Frame Tilting Device The upper roller frame can be tilted transversely to the strip's travel direction. This creates material stretching on each side.

Feed Systems

2-Roller Strip Feed The 2-roller strip feed is easily mounted onto presses and stamping machines. Both feed rollers are driven by maintenance-free AC servomotors. The upper roller is liftable. Precise feeding accuracy is achieved, and the feed can be programmed with different lengths in a sequence.

2-Roller Zig-Zag Feed The 2-roller zig-zag feed can be added to the 2-roller strip feed. It offers flexibility in cross-directional feeding for optimized material utilization, especially for coils with varying diameters. AC servomotors ensure precise feeding, and various feed and transverse paths are programmable as cycles.

Transfer

The KOHLER Transfer is a modular system that can be arranged above or below the transport plane, inside or outside the press. Its design allows for high production rates due to low inertia moments. The installation is straightforward, and the control is performed via an industrial PC with a touch-screen interface. Gripper rails are smooth-running and synchronized with the press, and the entire system can be freely programmed for movement and actions.

These technologies and systems collectively enhance the efficiency and precision of the long part production process, providing a comprehensive solution for various manufacturing requirements.