ASC LIGHTNING UNCOILER™
Eliminates the Coil Pit from High-Speed Purlin Rollforming

ASC Machine Tools has introduced the Lightning Uncoiler™, a new electrically driven, servo-controlled uncoiler designed specifically for high-speed purlin rollforming lines. Combined with ASC's servo-driven Feed Roll Tower, the Lightning Uncoiler™ creates a synchronized material-handling system that eliminates the need for a traditional coil pit.

For decades, high-speed purlin rollforming lines have typically required a deep coil pit between the uncoiler and punching unit. The pit provides a material buffer between the coil and the punching system during the rapid acceleration, deceleration, and stopping cycles required for punching.

The Lightning Uncoiler™ and servo-driven Feed Roll Tower change that approach.

By actively controlling the coil and synchronizing material movement with the punching system, ASC has developed a solution that allows high-speed purlin lines to operate without a traditional 8- to 10-foot-deep coil pit.

Why Do High-Speed Purlin Lines Traditionally Require a Coil Pit?

High Speed Purlin rollforming lines frequently incorporate servo-driven punching units. During operation, the punching system must rapidly pull material into position, stop it, punch the required holes, and then accelerate again.

This creates a challenge at the front end of the line.

Traditional purlin lines often use a drag-brake uncoiler. The coil has significant rotational inertia, particularly when processing large, heavy coils. When the Feed Roll Tower suddenly accelerates the material, it must overcome the inertia of the coil and the resistance created by the drag-brake system.

The same challenge occurs when the line stops.

The punching system can stop the material extremely quickly, while the coil continues to rotate because of its inertia. Without sufficient material accumulation between the uncoiler and the punching unit, these rapid changes in speed can create tension and synchronization problems.

The traditional solution has been to install a deep coil pit.

The pit provides a large loop of material that acts as a buffer between the relatively slow response of the drag-brake uncoiler and the rapid movement of the servo-driven punching system. While effective, the pit creates significant construction, safety, and facility-layout challenges.

The Lightning Uncoiler™ and Servo Feed Roll Tower Solve the Problem Together

The key to ASC's pitless solution is not simply replacing the conventional uncoiler. The Lightning Uncoiler™ works in combination with ASC's servo-driven Feed Roll Tower to actively control the material throughout the high-speed punching cycle.

The Lightning Uncoiler™ uses an electric servo drive to control the acceleration and deceleration of the coil. At the same time, the servo-driven Feed Roll Tower controls the movement of the strip entering the punching system.

These two systems work together as a coordinated material-control system.

Instead of the Feed Roll Tower pulling material from a drag-brake uncoiler, the Lightning Uncoiler™ actively controls the coil and synchronizes material payout with the Feed Roll Tower, providing precise material control throughout the punching cycle.

When the servo feed rolls on the punching system accelerate, the Lightning Uncoiler™ and servo-driven Feed Roll Tower work together to match the changing material demand. When the punching system stops, the Lightning Uncoiler™ rapidly decelerates the coil.

This precise coordination is made possible by ASC's proprietary control software, laser loop control, and real-time coil diameter measurement. These technologies allow the system to continuously monitor and coordinate the movement of the coil and material as production speeds change.

The coordinated control of all components minimizes the effects of coil inertia and eliminates the need for a large loop of accumulated material between the uncoiler and punching unit.

The result is precise, responsive material control without the need for a traditional coil pit.

Lightning Uncoiler - No Pit Required.JPG

Eliminating the Pit
Eliminates More Than Concrete

Groundwater Problems:

A traditional purlin coil pit can be 8 to 10 feet deep. In areas with a high water table, constructing such a pit can be difficult and expensive.

Customers may need specialized waterproofing, welded steel tubs, drainage systems, sump pumps, and other measures to prevent groundwater from entering the pit.

With the Lightning Uncoiler™ and servo-driven Feed Roll Tower, the production line no longer depends on a deep pit.

Improved Workplace Safety

Open floor pits introduce workplace safety concerns, both during initial construction and throughout the life of the production line.

During construction, excavating and working around a deep floor pit creates additional hazards for contractors and employees.

Once the pit is in operation, it must typically be protected with safety guarding, railings or other safeguards. Even with these measures in place, there remains a risk of an operator or other employee failing to follow established safety procedures and falling into the pit.

Depending on its configuration and depth, a pit can also introduce the potential for hazardous atmospheric conditions.

By eliminating the need for a deep floor pit, the Lightning Uncoiler™ helps remove these hazards from the production environment while reducing the associated construction requirements and simplifying overall safety planning and training.

Greater Factory Layout Flexibility

A traditional coil pit permanently defines where portions of the rollforming line must be installed.

Once a pit has been excavated and constructed, relocating the equipment is difficult and expensive.

A pitless system provides significantly more flexibility.

Manufacturers have greater freedom when determining the location and configuration of their production equipment, while future plant modifications and equipment moves can be easier to accommodate.

Lower Installation Costs

Constructing a large industrial pit can require excavation, concrete cutting, reinforcement, waterproofing, drainage, engineering, and specialized construction work.

The ASC pitless purlin line eliminates the need for this specialized floor construction.

Customers can install the equipment directly on the factory floor without the expense and disruption associated with excavating an 8- to 10-foot-deep pit.