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COIL MASTER

COIL MASTER
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METALS INDUSTRY SYSTEMS EUROPE CoilMaster “Through the Eye” Coil Packaging System The CoilMaster packaging system represents a major advance in the packaging of steel and aluminium coils with the application of microchip technology and innovative engineering. It is an automatically operated system that uses a heavy gauge stretch film for the wrapping of coils. The concept used is for a specifically shaped track to carry a film dispensing shuttle through the eye of the coil, while the coil is slowly rotated on its axis on a set of blocker rollers (Fig 1). The complete body of the coil is, therefore sealed by a cocoon of stretch film. Ancillary protective packaging can be incorporated into the system. The system can be tailored to wrap almost any size of coil; it is flexible in terms of location requirements. It can remain stationary with coils presented by crane, C-hook or truck to a mobile coil car that traverses into a packaging station. Coils can also be brought to the station by walking beam, coil car or conveyor. The system can also move in and out, positioning itself alongside a packing station, or mounted on an overhead crane track or on floor rails enabling the system to move to several stations. Blocker rolls are incorporated into the packaging station and can be either stationary or mobile as well. Fig 1 Through The Eye CoilMaster Wrapping system CoilMaster is proven technology for wrapping coils axially through the eye. Developed originally by KC Metal Products and BHP in Australia, this system is now manufactured and marketed throughout the World by Signode CoilMaster, and its licensees in North America and Japan. Concept The package concept is an integral part of the CoilMaster design. The system puts a tight layer of film over all surfaces of the coil. This tight layer of film eliminates most of the air from the package. By reducing the amount of air in the package, the potential for moisture to form is reduced, thereby reducing the possibility of corrosion or water spots. The ancillary packaging is then applied. This packaging may include inside diameter protectors, outside diameter protectors, side wall protectors or belly wrap material. This material can be applied manually or its application can be integrated into the system to be applied automatically. This ancillary packaging protects both the coil and the first layer of film The ancillary product can be made from plastics to maintain a completely recyclable package. A second layer of film is then applied. The second layer of film holds the ancillary package in place and further protects the inner airtight layer of film. Since the two layers are applied separately and the ancillary material is in between, the outer layer may be torn from handling damage but the inner layer remains intact and thus the coil stays sealed and protected Also, since the. first layer of film is tight if, any condensation forms, it is either between the layers or on the outside layer. In either case, the moisture does not penetrate through the first layer. Also, since the entire coil is sealed in a waterproof package, any external moisture runs off the package. System Design To achieve this process, the CoilMaster has two heavy-duty, opposing, C-shaped track sections that, when closed, provide the guide for the film-dispensing shuttle (Fig. 1). These are arranged to be adjustable in the vertical plane to accommodate basically all coil diameters and are mounted so that the two half-sections may be separated to allow the coil to be positioned. The C-frames are opened and closed using screw jack actuators. The film dispensing shuttle is designed to drive itself around the track (rack and pinion system) at a speed up to 4.2 m/s. Power is delivered to the track through conductor rails. A 50/60-Hz motor is mounted on the shuttle. The stretch film is drawn off the film roller through a film accumulation and conditioning system, thereby applying stretch film to all points of the coil at an even tension The film is a heavy gauge, linear lowdensity polyethylene stretch film specifically designed for this application. A VCI chemical additive to prevent corrosion is incorporated into the film in the extrusion process.

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METALS INDUSTRY SYSTEMS EUROPE The blocker rolls, which are polyurethane covered, are electrically driven through a reducer and. chain and sprocket, utilizing a frequency inverter to Control the speed. Blocker rolls can also be hydraulically driven. Machine control system A Programmable Logic Controller (PLC) controls the system. The PLC allows a variety of wrapping programs to be programmed according to the wrap profile required, including fully automated or manual controls for all operations. Different film overlaps or number of laps required can be programmed, depending on the pack...

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METALS INDUSTRY SYSTEMS EUROPE • • • • • • Relatively low labor for packaging. Potential to eliminate eye bands. Flexibility in system design. Environmentally friendly package that can be unwrapped in under a minute, and the material is recyclable. Increased yield from coils for customers. Safer work environment resulting in fewer injuries. Summary CoilMaster is proven technology for wrapping coils axially through the eye. Coils are loaded onto driven blocker rolls, scanned to measure the diameter, and data sent to a PLC. The wrapping process is then executed with the touch of a button. The...

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