Tag Archives: coil-handling

Replacement Parts from Coiltek®

A line is a big investment, and when it goes down, you loose money. That’s why we strive to make products that stand the test of time. Many of our boards have lasted in the field for over 15 years. In fact we have seen many boards sent in for repair that are over 20 years old, and many of those can actually be repaired.

For those times when a repair just isn’t fast enough, we also supply replacement boards. We keep all of our boards and cables in stock at all times so that we can get you up and running again ASAP.

We also design all our equipment to be backwards compatible. That means that even if your loop control is 20 years old, if the stand is still in tact, you can just replace the boards with our new CB-5501M control board and CB-5101R-1 ranging card, and bring your unit back to life.

If you have any questions about replacement boards or repairs, or to request an RMA number for your repair, please contact us. For more info on Coiltek, our high-quality, American made loop control systems, check out our main site.

Coiltek® Downloads Page

We get a lot of phone calls requesting new copies of manuals and enquiring as to where our signature software can be obtained. Both of these items, and much more, including brochures and trouble-shooting materials, can be downloaded for free from our website on our Downloads page.

If you need any further information, have a question, or a new application, let us know by contacting us.

Coming Soon: Resource Content

Here at Coiltek®, we are always trying to make life easier for our customers. To that end, we are working to create content that allows our customers to easily and quickly find information pertinent to the issues they face regularly.

If you have a question or application that you would like us to explore in this series, please contact us. As always, more information about our quality, US-made loop control systems can be found at coiltek.com.

CS-5000-54XX

The standard Coiltek loop control model, the CS-5000, comes in three different stand heights. Last time I discussed the benefits of the CS-5000-15XX, which comes with a 15″ tall stand and a customer-dictated boom length (represented by the XX in the name). This time, we will talk about the next size up, the CS-5000-54XX.

The CS-5000-54XX, as the name suggests, features a 54″ tall stand and a variable boom length, which is dictated by customer need. If, for instance, you need to position your loop control further away from the line or have wide stock, choose a longer boom. If you want your stand closer to your line, choose a shorter boom. When ordering a stand, the XX in the part number can be replaced by the chosen boom length. You can choose between many boom lengths, from 11″ to 48″. The most popular combination boom length for the 54″ tall stand is the 11″ boom, otherwise known as a CS-5000-5411.

The CS-5000-54XX can be used over pits, if necessary, and with a variety of different materials, from steel to plastic tubing. This reliable, adaptable system can also be used with a world of accessories to enhance its performance, such as the CTAC-2 sound isolation cone, the Hammerhead multiple transducer assembly, and the 3CPO, which grants remote access to 3 preset programs.

For more information on any of our products, including the entire CS-5000 series, please visit our main website, check out our brochures, and of course, don’t hesitate to contact us.

Custom Equipment

At Coiltek we specialize in loop controls, but it’s not all that we can do. Our other specialties include winding equipment, rewinding, paper tensioning, converting, custom equipment, and engineering services.

Our expert team has created everything from massive machinery with powered hydraulics, to a simple magnetic coil lifter for safely disposing of damaged stainless steal. If you can dream it, we can draw, fabricate it, and deliver it at a reasonable price.

For more information on our capabilities, check out our custom machinery page and then contact us. We look forward to working with you on your next project.IMG_0063

“Free Loop” Controls

At Coiltek our loop controls are designed as no-touch controls for free loops. A free loop is an unfettered drop off of coil stock – slack in the line – before it enters into a process or is rewound.

The advantages of no-touch loop control systems are many, and have been discussed at some length in previous posts, but one of the major advantages is for use with non-conductive stock, such as extruded rubber or plastic medical tubing.

Our sensitive non-contacting, ultrasonic loop controls can be used on everything from wide stocks to very thin stocks. Coiltek loop controls can also be used with a variety of materials because, in addition to being very sensitive, our loop controls are adaptable.

For use with stocks that move either horizontally or vertically, we created the Hammerhead Accessory and the CS-5140 to ensure the stock is always within range. Additionally, each Coiltek loop control is essentially a custom build. We have several lines of loop controls, including a low-cost ultrasonic control, a stand-less line of loop controls, and our standard product line, the CS-5000. Each CS-5000 is fully customizable, as the customer chooses the height of the stand (either 15″, 54″, 72″, or 84″) and boom length (choose from 9 lengths between 11″ and 48″). This flexibility allows our loop controls to work with everything from tables to pits and everywhere in between. Since our no-touch ultrasonic loop controls rely on sound waves, not electrical contact or photo-technology, reflective stocks and non-metallic stocks are no problem.

To learn more about our loop controls, please visit our products page or view our brochures. Please feel free to contact us with inquiries, RFQs, and new applications.

Ultrasonic Control Systems

Coiltek ultrasonic loop control systems are not limited to only controlling the speed of a decoiler or straightener. In fact, any variable output device that accepts 0-10 VDC input can be controlled by our loop controls. This means that Coiltek control systems can be used to control loop height, as well as many other applications such as the level of a substance in a tank, in addition to its normal function in controlling feeding for paper processing, feeding on stamping lines, and loop control for rubber extrusion and plastic tubing manufacture.

If you have a new application that you’d like to try out with one of our units, please let us know. We have consignment terms available for customers with good credit references. To learn about our product lines, visit our products page and browse our brochures. To learn more about any unit and for up-to-date pricing, contact us.

Custom Machinery

In addition to our standard line of loop control systems, we also create custom machinery. With our expert engineering and efficient techs, we are able to manage every aspect of custom equipment from design through manufacturing in one location. Our experienced team has created everything from magnetic lifts for moving stainless steel coils, to a hydrolic-lift system for motor stator production, and a line for winding extruded rubber.

We are experts in winding and rewinding and have put that expertise to work in producing custom slitting and paper processing equipment, and even machinery to create magnetic advertisements.

We also have experience in freelance engineering work. We can design items which can then be built in a facility near you.

If you have an application that you’d like to speak with us about, feel free to contact us. You can also learn more about our capabilities on our Custom Equipment page.

Coiltek Loop Controls

Coiltek makes ultrasonic loop controls, which are sometimes known as sonic loop controls, sonar loop controls, and no-touch loop controls. Our founder invented the concept of using ultrasonic frequencies to sense and control the height of a loop during processes such as stamping, winding, rewinding, and extrusion and our loop controls have been the industry standard ever since.

If you would like to explore our products, please visit the Products and Brochures sections of our website. Any further questions? Contact us.

The 3CPO Accessory for Coiltek Loop Control Systems

The 3CPO option allows for easy-access to multiple stored programs.

Coiltek’s CS-5000 ultrasonic sensor has always had the capability of storing multiple loop control parameters.  The 3CPO option makes it easy for press operators to quickly switch to the appropriate loop control algorithm to run the job.

Why would you need different loop control parameters?  Here a few examples of press jobs that beg special treatment.

  • Long Feed Progressions.  If each press cycle pulls most of the slack from the loop, your loop control algorithm should include offset.  With offset, the control signal from the CS-5000 jumps from zero volts to some percentage of full scale output.  Figure 1 shows a comparison of a standard analog output with a 30% offset output.  With offset, the feed equipment (decoiler or straightener/flattener) gets a substantial move signal before too much loop is depleted.  This head start overcomes the  inertia of the equipment giving it more of a chance to match the press throughput.   With offset set properly, the feed device will run more smoothly.  Here’s why: The loop will swing up and down dramatically with each stroke of the press.  This is an unavoidable. The loop control will sense the large fluctuation.  Note that with offset, the output signal over the control range presents a gentler slope than a pure 1:1 analog output.  Provided the loop stays within the desired control range, the drive that the CS-5000 controls will exhibit far less “wow” (variation in speed with each press stroke).  Offset works best with constant speed devices like straighteners or nip-pullers than with decoilers.   The dwindling radius of the coil represents a constantly changing system gain, which can make the offset characteristics difficult to dial in.
  • Thick stocks.  In a given looping area, thin stocks ‘drape’ better than thick stocks.  In fact, if there is insufficient looping distance, thick stocks cannot be pushed all the way to the floor without imposing set (curvature) in the material.  Where a straightener/flattener is used to remove coil-set, it’s hardly good practice to re-institute it in the loop.  It’s critical then, if you run different stock thicknesses through the same press, that you set different control ranges to adapt to material thickness.  A preset program associated with a particular stock thickness  lets you control the radius of curvature in the loop so that stock bending stress is kept below yield.
  • Short Feed Progressions.  When a straightener, designed to keep up with high press throughputs, is presented with a very short feed progression or slow press SPMs, a standard loop control algorithm  can cause problems.  The straightener will grind along at a small fraction of its rated speed. Without ventilation from its internal fan the motor overheats.  At best, the thermal cutouts snap, and the straightener’s down.  Usually, the motors just burn up.  The CS-5000’s control relay lets you program an ON-OFF system with hysteresis  Using the control relay, the straightener turns on when the loop rises to a predetermined height, then stops when the loop drops below a certain level (see figure below).  This way the straightener is ON at a reasonable speed for a while, then rests. In the figure below the diagonal arrows in the time graph indicate whether the loop is depleting (arrows point UP) or re-filling (arrows point DOWN).

This algorithm is a little more complicated to program and wire.  If your line requires this feature, refer to our white paper entitled Accessing ON-OFF Control Within the 3CPO Option.

Programming the CS-5000 series controls for multiple program presets can be performed manually with the on-board DIP switches.  Full functionality including programming OFFSET or the Control Relay must be performed using Coiltek’s CSWin32 software.  It’s a free download from this website.  The 3 CPO option is available pre-installed on our CS-5000, CS-5100 or even our CS-6100 series controls.  It is also sold as a simple-to-install kit.

To learn more about the 3CPO option, check out our full brochure, complete with pictures and diagrams. As always, feel free to contact us with any questions you may have about your application. Click here to find all our contact information.