Conventional Systems
A conventional line consists of a servo feed, a powered straightener and a pull-off coil reel with or without a coil car. A conventional line's versatility is a huge advantage. A wide variety of material widths, thicknesses, and tensile strengths can be run on one line. Special speed controls can ensure the straightener keeps running so as to avoid damaging surface-critical material. Safety devices for containing thick material are available. "One button" automated setup is optional. Adding a pull through straightener to the feed can further enhance versatility by allowing very thick and very thin material to be run on the same line.
Space Saver Systems
SmartSaver
For many applications, SmartSaver can save as much as 50% of the floor space required by a conventional feed line without making sacrifices in performance! SmartSaver is not just limited to the small stuff. Lines can be designed to handle material up to 72” wide, high strength steel and coil weights up to 60,000 Lbs.
 |
This SmartSaver line is rated for 24" wide x .165" thick mild steel and up to 10,000 Lbs. coils. The simple coil threading and compact design make it great for a wide range of stamping operations. The straightener has full pilot release, making this line ideal for progressive die applications. |
Rated for 40,000 Lbs. x 72" wide x 4mm thick high strength steel, this SmartSaverHD line beefy and compact. The line is heavy-duty and includes a powered feeder/straightener with full pilot release, allowing it to be used in both transfer and progressive die applications. The large pinch roll on the reel drives the material into a loop. The HD version of the SmartSaver is a great choice for wide, medium thickness, high strength materials. |
 |
Paddle Loop
This design combines a servo feed with a pull though straightener or a servo powered feeder/straightener with a powered reel. A slack loop is developed below the spindle, reducing floor space significantly compared to conventional slack loops. For thicker materials, an optional hold down arm/peeler/threader/debender assembly is used for "hands-free" threading. Pilot release for the upper straightener rolls is available and recommended for progressive die applications.
 |
This amazingly compact line takes up only 16 feet, yet is rated for 48" wide x 35,000 Lbs. coils! This system is designed for lighter gauge materials needing to be run in a compact setting. By developing the loop below the spindle and incorporating a feeder with a pull through straightener (NOTE: "feeder with a pull through straightener" should be hyperlinked to this section), this line a real space saver. |
|---|
This system is rated for up to .250" thick material. The line includes a Power-Core Series powered feeder/straightener (NOTE: "Power-Core Series" should be hyperlinked to the Powered feeder/straightener page) and a 20,000 Lbs. capacity reel and load car. Including the stand-alone hold down arm/peeler/threader/debender promotes safe and efficient coil threading.
Synchronized
A Synchronous line is a conventional feed line, but with one significant difference - NO LOOP! Thus, a line that may normally require 45-50 feet of floor space and the expense and hassle of a looping pit instead requires only about 30 feet with no pit. A highly sophisticated control package communicates press speed, feeder speed and required straightener speed automatically. The straightener and feeder provide material to the press simultaneously, thus eliminating the need for the slack loop. |
 |
 |
Another synchronous line concept employs a feeder/straightener instead of a separate feeder and straightener. This reduces the floor space even more significantly. In fact, the middle photo (see photos) is capable of running .394" thick high strength material in only 23 feet! |
High Strength Steel Lines
High strength steels require special considerations be taken when building a feed line. The photo below shows a line rated to run 36" wide x .500" thick material with a yield strength of up to 120 KSI! It employs two straighteners - one in the base of the cradle having 8" diameter rolls, one at the feeder with 5" diameter rolls - for maximum versatility. High strength steel requires significantly larger straightener rolls and roll spacing that same thickness mild steel. Feed Lease is an expert at running HSS. Our "Engineered Solutions" approach to our customer's applications is especially necessary when evaluating the best equipment for HSS.
The photo at right shows a space saving method for running high strength material. This unit is rated for a maximum width of 42" and can run up to .394" thick material at 85 KSI in only 23 feet! It employs one of our servo powered feeder straighteners with hydraulic pilot release and a massive upper straightener roll assembly specially designed for the heaviest, high tensile material available today!! Truly this is an unmatched system for running heavy gauge, high strength material in a space saving environment. By employing a secondary, pull thru straightener, the system can also run lighter gauge materials. |
 |
THE BEAST - This massive coil line is rated for 60" wide material x .250" thick (36" x .500") at a hardness of up to 120 KSI. This line feeds a massive twin, 2200 ton tandem transfer press. The straightener in the base of the cradle has EIGHT INCH diameter straightener rolls and the side plate is 3" thick! The cradle can handle 40,000 Lbs. coils and includes many safety and peeling devices to keep operators safe and coil threading efficient. The servo feed also has an additional straightener behind it to add additional straightening ability to the system. The overhead deflector system eliminates the need for a looping pit and keeps the line modular. Truly a massive line for heaviest, high strength material.
.
Specialized Control Solutions
The system is designed to work with virtually no slack loop.
The feeder drive (b) and the straightener drive (c) are both synchronized through a sophisticated servo drive platform. The two drives function in a "push-pull" format wherein the required feed progression is simultaneously provided by both the feeder and the straightener. Both the feeder and the straightener have closed-loop position encoders to ensure maximum reliability and excellent feed length precision. This type of system will work for long and short progressions (although in most instances, the coil reel will also need to be servo driven to ensure the best accuracy). A press mounted encoder (a) allows the system to automatically match the press speed as it constantly monitors crank position. |
 |
 |
|
|
|
|
|
This platform has a unique "peer-to-peer" connectivity, allowing the two drives to communicate directly with each other through a high speed networking protocol.
A Feed Lease-supplied rotary encoder (a) (optional) constantly senses the press' crank position. This position reference is sent to the servo feeder's drive (b) thereby integrating the press and feeder. Since the feed always knows how fast the press is running, it will automatically compensate for changes in press speed (this system is also ideal for link-motion presses). The powered straightener drive (d) is upgraded to the same servo platform as the drive in the feed. Once upgraded, the straightener drive will receive an average line speed pulse from the feeder's drive. In this way, the straightener now knows how fast the feeder is actually going, rather than simply receiving a signal from a non-integrated loop control (e.g., ultrasonic, loop arm, loop lights, etc.). An ultrasonic loop control (c) is included as a backup and also provides a position reference to confirm that the two drives are communicating properly. |
 |
|
|
|
|
Allows for "one button" setup of entire feed line
|
|
 |
Any powered axis may be automated
Through customer supplied internet connection, service can be performed and setup altered.
|
|