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coil-handling-compacting

The coil handling and compacting machine, which compresses large coils of wire and then secures it with either, wire binding or steel strapping, required a redesign.

hydraulic-control-system-compactor

Client engineers and the engineering team worked together designing needed changes to the hydraulic control system used on the compactor.

hydraulic-power-unit-filtration

To match the filtration level of the hydraulic power unit, the team chose low leakage poppet style pilot operated check valves to replace the DIN valves.


 

Coil Handling & Compacting Machine
Required a Redesign & Reconfiguration

Sorensen Systems Ships Machinery Worldwide

When a major U.S. machine manufacturer experienced a challenge at its China wire drawing mill, from a malfunctioning coil compacting system, engineers at Sorensen Systems responded with a machine assessment that led to a redesign and reconfiguration to bring the equipment within its original design specifications.

Inconsistent Compacting

The coil handling and compacting machine, which compresses large coils of wire and then secures them with either wire binding or steel strapping, was not working correctly. The machine had developed an inconsistent compacting force and coil positioning. In describing the problem, the chief engineer at Sorensen Systems described the problem as "the 'hands' of the compactor would come together to squeeze the coil, but the force of the one 'hand' would push the other out of position."

Redesign Control System

Client engineers and the engineering team worked together designing needed changes to the hydraulic control system used on the compactor. Both sides of the compactor would come together to squeeze the coil, but the force of one side would periodically push the other out of position. Additionally, force control was erratic due to inconsistent pressure control. Both issues combined to produce coils with inconsistent compaction and resultant potential damage to the coil.

Replacing DIN valves

After analyzing the circuit and the power unit, the first issue of inconsistent positioning was determined to be a result of using large DIN cartridge valves, whose performance is susceptible to dirt and debris in the system. To match the filtration level of the hydraulic power unit, the team chose low leakage poppet style pilot operated check valves to replace the DIN valves. In order to meet the expected flow rate requirements two poppet PO checks were installed in parallel for each DIN valve.

Inconsistent Pressure Issue

The issue of inconsistent pressure control was found to be caused by over pressurization of the system during initial cylinder approach. Specifically, the cylinders were run in regeneration mode for the initial approach and dropped out of regeneration mode for final compaction. However, due to system resistance the pressure required for regeneration mode was greater than that required for final compaction. Because control of pressure was being accomplished by a proportional pressure relief valve – lowering the pressure set point at the time of compaction resulted in periods of instability as the valve attempted to lower the system pressure to the desired level – adversely affecting compaction force.

Solution Achieved

The solution was achieved with the replacement of the existing valves with faster, larger proportional directional and relief valves, along with a wholesale redesign of the manifold, simplification of the hydraulic circuitry, and enlargement of associated piping and hoses, which resulted in lowering regeneration system pressure to levels well below compaction pressure, greatly improving compaction reliability. Once the redesign was completed, the hydraulic control system was assembled, tested and packed for shipment to Shanghai, China.


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