Tag Archives: stamping line

Free Software from Coiltek®

Did you know that your Coiltek® ultrasonic loop control can be set up with your laptop? You can use our free CSWin32 software to set your presets and connect via USB directly to your non-contact loop control. Then accessing your programming is as easy as flipping a DIP switch.

Even better: Our software is a free download on our website. Just visit the Downloads section of our website, click on Software, and select the version you need to work with your version of our mainboard. In no time you’ll be remotely programming your no-touch loop control system.

As always, should you encounter difficulty or have questions, please contact us.

“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.

A brief history of ultrasonic loop controls

In the late 1970s two men had the same great idea at the same time. One of those men was Hall Cary, the founder of Coil Technology, Inc.

As an acoustical engineer, Hall had already founded the Cary Corporation, which specialized in manufacturing sound isolating enclosures for press lines and other equipment. Well-versed in the physics of sound, he thought that perhaps sound waves could be harnessed for use in manufacturing processes.

The result of this line of inquiry was the original Coiltek ultrasonic loop control. Using an ultrasonic element to transmit and receive sound waves, the device could accurately gauge distance. By coupling this ability with the ability to create a variable 0-10 VDC output based on the distance of an object from the element, the ultrasonic loop control was born.

To learn more about why non-contacting or no-touch loop controls are such an important innovation and the advantages of a Coiltek loop control over the competition, feel free to contact us. For a full list of our current products, please visit our products page or check out our brochures.

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.

Loop Controls

Here at Coiltek our standard product is loop controls. It’s really true that if you are going to make one thing, you should make it well, and we do. Our loop controls are the industry standard in manufacturing. From stamping lines to extrusion, converting to processing, our loop control systems are the go-to.

Our standard product line is the CS-5000 ultrasonic loop controls, a unit with a stand and customizable boom length. The CS-5100 is the stand-less version of the CS-5000 loop control. It comes with an electrical enclosure connected via a 15 foot cable to the ranging card in the boom. Additionally, we make a low-cost sonic loop control called the CS-6200 series. For more information on any of our loop control systems, please see the products and brochures sections of our website.

Questions? Concerns? New Applications? Please 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.

Coiltek Hammerhead Accessory

At Coiltek we’re always trying to find innovative solutions to industrial problems involving loop controls. One such innovation is our Hammerhead accessory for the CS-5000 series of ultrasonic loop controls.

The only one of its kind, the Hammerhead features 3 ultrasonic elements which, when the kit is attached to the boom of the unit, are seated in a line parallel to the stock the unit is sensing. This innovative design triples the sensing area of the CS-5000 in order to sense stock continuously even when the bottom of the loop moves vertically throughout the process.

To learn more about the Hammerhead Accessory, as well as our other offerings, please visit our Products page. You can also learn more about our loop control systems by checking out the brochures in the Downloads section of our site. If you should have any questions or would like to request a quote, please don’t hesitate to call us or drop us a line using the widget on our Contact Us page.

Terminology in Loop Control Systems

With so many manufacturers and so many kinds of loop controls in the market, it can be hard to figure out just what you need. This post is meant as a guide to help you sort through the terminology to arrive at the right system for you.

The first distinction to make is that between no-touch and touch-probe systems. A touch probe works by sending electrical signals when touched by material and is often able to be used only with conductive materials like metal. A no-touch loop control is more flexible, as it senses using lasers or, in the case of Coiltek loop controls, sound waves to sense distance, adjusting a 0-10V output based on the distance from the sensor.

Most confusing of all, is that many times there are many words describing the same technology. For instance, different manufacturers will refer to the same technology as an ultrasonic loop control or a sonic loop control.

If you have any further questions about how to decode the terminology surrounding loop control systems to determine which system is right for you, please contact us at info@coiltek.com.

Coiltek Loop Controls

The standard product line for Coiltek is ultrasonic loop control systems. Sometimes called sonic loop controls or no-touch loop controls, these products control the speed of an unwinder or straightener using a 0-10v output controlled by the loop height.

Our Coiltek sonic loop controls, like the CS-5000, are used worldwide on press lines. You can find our no-touch loop control systems in plants from Thailand to Turkey. We work with major suppliers of press lines, such as Coe Press Equipment and Press Line Equipment as their supplier of no-touch, sonic loop controls.

Our founder came up with the idea for the sonic loop control in the 1970s and started the company out of his garage. As the need for no-touch loop control systems expanded, so did our company. Today our American made sonic loop controls are found from Mexico to Europe.

If you would like more information on our sonic loop control systems, check out our website and see our brochures page, or write us at info@coiltek.com, or use our simple Contact Us widget.