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Custom Sheeting System
Model: Sheeting System
Models
This custom Sheeting System takes an extruded film and indexes and cuts the sheets to lengths in increments up to six digits. After the sheets are indexed and cut, an automated stacking system will create stacks onto a tray system provided by the customer with AZCO’s guidance. The tray system will accommodate all varieties of cut lengths and widths into a master tray.

The process begins with the extruded web entering the AZCO Accumulator. The accumulator is equipped with a multitude of rollers and a dancer system to maintain proper web tension. The accumulator is designed in such a way so that operators have sufficient access to thread the web.

Positioned directly after the accumulator, is the AZCO FG1000 Cut to Length unit which cuts the material.

As the sheets are being indexed thru the knife assembly, a gripper system gently grips the crosscut edge of web and pulls the web back to the stacking station at the same rate that it is being indexed forward. Once the guillotine knife assembly has performed its cut, the gripper system will take the cut sheet to the final position on the stack. When, the sheet is placed on the stack, the gripper will index back to the knife assembly and wait for the next sheet to repeat this process.

The automatic stacking station is positioned directly after the AZCO FG1000 cut to length unit. The height of the station is motor controlled to provide precise adjustments. A series of optical sensors are installed to ensure proper operation.

The cut to length unit is equipped with a light tower to alert an operator when the tray is nearly complete. When the tray is full the unit will activate the accumulator and the cut to length will suspend operation giving the operator time to remove the full tray from production and replace with an empty tray. After tray swap the unit will resume cutting and feeding the web.


Benefits
  • Static charge to base of knife assembly is prevented by allowing laminar airflow of ionized air to float the product through the knife assembly
  • Knife assembly requires 80 psi of clean shop air and 110 volt to power the ionizer power supply
  • Lexan enclosure included on knife assembly to provide safety
  • Servo driven motor drive rollers
  • Gripper fingers coated on gripper assembly to protect product
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    Options
    • Knife assembly hardened tool steel blades
    • PLC integrated film loop detection will incorporate a 3 eye system:
    • Hard Coat 6061 aluminum roller material
    • Knife assembly has pneumatically pre-loaded top idler pinch roller
    • Station capable of handling a 6” tall stack of sheets, incrementally adjustable 12” to 41” and 300/800 micron thick, weighing a maximum of 300 lbs.
    • Automatic shut down when no product sensed entering rollers or exiting knife assembly
    • Linear ball bearing bushings
    • PLC controlled; operator control panel with color touch screen operates on 110-230 volt, 50 or 60 cycles; HMI for easy setup and operation of the unit
    • Precision ground ball bearings - clean room compliant and require no lubrication
    • Unit aligned and mounted to floor
    • Pneumatic air is filtered, non-lubricated
    • Stacking station provides automatic electic pallet lift
      • Load rating: up to 300 lb loa
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      • Controlled from PLC
      • Capable of multiple, adjustable height set points
    • Sensor to detect tray
    • Sheet edge guides manually adjustable 24” to 30”
    • Tray platform has low friction surface
    • Stack sidewall: reasonably and routinely achievable sheet to sheet offset can be up to .187”
    • AZCO can provide a supporting technical role in the development of a tray system with the customer

      Specifications
      • Minimum of 4” or 6” roller diameter on accumulator
      • Accumulator can accumulate up to 30 feet of film at the maximum extrusion rate of 25 feet per minute
      • Acceptable film entry height to accumulator: 3 feet minimum, 4 feet maximum
      • 1000mm cutting area (39.33”)
      • Sheet length tolerance: +/- 0.12 inc
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      • Sheet square-ness tolerance measured on a diagonal: +/- 0.25 inch
      • Knife assembly that generates a minimum of 300-400 lbs per inch width
      • Stacking station capable of handling a 6” tall stack of sheets measuring (width 24”-30”) and (length 12”-41”); 300/800 micron thick, weighing a maximum of 300 lbs
      Accessory

      Material
      • Polycarbonate extruded film, 0.034” thick, up to 31” wide
      • Cut lengths are incrementally adjustable 12” to 41” for production sizes
      • Sample sheets 60” are available for quality control

       

      WARNING!!
      UNIT MUST BE PROPERLY GUIDED AT ALL TIMES TO MEET ALL STATE, FEDERAL, AND LOCAL REQUIREMENTS