Tag Archives: straighteners

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.

“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.

Advantages of Coiltek Ultrasonic Loop Controls

The advantages of Coiltek loop control systems are plentiful, but today we will focus on three major advantages: No-touch feeding control, durability, and programability.

Coiltek makes the industry standard ultrasonic loop control systems. Our CS-6200 series of low-cost loop controls and our popular CS-5000 series of ultrasonic loop controls provide a 0-10v output to control the feeding of a straightener or decoiler, allowing for consistent feeding without touching the stock. This is an advantage especially for stocks that move a lot during feeding, such as wide stocks, and for non-conductive stock, such as plastic tubing or extruded rubber.

Coiltek products stand the test of time and it is not unusual to see a unit in a plant that is more than a decade old. In fact, our shop regularly receives inquiries about updating working systems built over 15 years ago. We stand behind our product and offer free lifetime phone support for every product we make. We also repair our old boards to save our customers money. All of our new products are backwards compatible, meaning that any time you decide to update your system, you will be able to find parts that work.

Finally, our Coiltek units make switching between stocks and their respective programs easy with on-board storage of up to 7 preset programs. We even offer an option to make 3 of those presets remotely accessible, called the 3CPO.

If you have any questions about what the durability, flexibility, and adaptability of Coiltek loop controls can do for your business, 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.

Loop Control Terminology

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 distrinction 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 the terminology surrounding loop control systems to determine which system is right for you, please contact us at info@coiltek.com, or use our handy contact widget.

Compatible Devices

Coiltek’s loop controls work to control loop height by emitting a 0-10V supply, causing the feeding or rewinding equipment to speed up or slow down to keep the loop within acceptable parameters.

Our loop controls work with decoilers and straighteners at the front end of the line. Plus, with take-up mode pre-installed on each board, it’s easy to use our loop controls with rewinders at the back end of a line when needed.

Coiltek loop controls are used in a variety of industries from rubber extrusion and press lines, to applications requiring thin stock sensing, such as the medical tubing industry.

As always, if you have any questions about Coiltek loop controls or want to know if our systems will fit your application, e-mail us at info@coiltek.com or use our simple contact widget.