SERIES 3000 FILMWRAPPER
MACHINE DESCRIPTION
The Series 3000 is a new design in film wrapping machines. Based upon input from the synthetic rubber industry and is designed to meet today's needs for faster wrapping, less film consumption, and better seals.
The Series 3000 film wrapper is fast; speeds of up to 8 bales per minute are comfortably achieved. This means one wrapper can often service two balers.
Film consumption is an issue when using a bale wrapping machine. A Sage Automation Series 3000 film wrapper utilizes a 24" diameter, 40-42" width film. This reduces the cost of the film, resulting in cost savings of about 10% per year. The series 3000 wraps the bales in the transverse direction, eliminating the "tails" on the long dimension of the bale. This reduces the amount of film used to wrap the bale by 10-12%.
The quality of the seal is probably the most important aspect of a bale wrapping application. The series 3000 forms its seals by clamping the film, cutting the film and then sealing the film in a relaxed (i.e. not under tension) condition. We use constant temperature sealing, which is very reliable and provides a consistent high quality seal.
The Sage Automation series 3000 film wrapper will save thousands of dollars per year in film costs, and time saved by fewer roll changes. The consistent wrap quality will lead to less product contamination, bale adhesion, and deliver consistent bale wrap coverage day after day.
MACHINE FOOTPRINT
DESIGN SPECIFICATIONS
The Stationary Structure
The frame and conveyor sub-assembly defines the stationary structure, and consists of:
· The main frame
· The infeed interface conveyor
· The pusher
· The outfeed interface conveyor
· Safety fencing and machine guarding
A typical structure would consist of a welded frame made from steel plate, and structural tubing. This ensures a long life and minimal maintenance. The Series 3000 bale wrapper is designed to stand up to the harsh environment of an industrial rubber plant. The frame supports the Series 3000 bale wrapper and transfers its weight to the foundation through large footpads. The footpads can be epoxy grouted in, or anchored with standard compression anchors.
The infeed and outfeed interface conveyors are produced from high quality conveyor components. The drive system for the conveyor is a chain driven live roller system that uses precision grease lubricated gear reducers. The conveyor rollers have sealed bearings, which do not require lubrication. Exit conveyor not included with this proposal.
The pusher is the mechanism that pushes the bale through the wrap zone. The pusher rotates on sealed bearings and is driven by a precision, grease-lubricated gear motor.
Great care has been taken to ensure that the Sage Automation series 3000 bale wrapper is a safe product when used properly. Fencing and guarding is in place to keep workers out of areas where the machine could cause them harm. The access doors are electrically interlocked into the e-stop circuit.
In order to safely access the machine, it should be put into e-stop after any bales are finished cycling
through it.
The Fundamental Moving Assemblies
The moving assemblies of a Series 3000 bale wrapper are made up of 4 basic sub-assemblies.
· The upper web drive
· The lower web drive
· The heater and seal
· The pop-up roller assemblies
The upper web drive sub-assembly serves as the drive for the upper film roll, and as a film tension system, used to deliver film to the wrapping zone.
The lower web drive sub-assembly serves as the drive for the lower film roll, and as a film tension system, used to deliver film to the wrap zone.
The heater and seal sub-assembly serves as the film sealing system, and forms the wrap zone. The wrap zone is the area where the bale is wrapped and sealed. The heater bars and the seal surface are pneumatically actuated until they come together to form a seal around the bale.
The pop-up roller sub-assembly serves as the transfer system with the pusher to transfer the bale through the wrap zone.
The Mechanical Drive Components
The mechanical drive components consist of 4 groups of components:
· Gear Reducers
· Drive Sprockets & Idler Sprockets
· Drive Belt
· Drive chains and conveyor chains
The Gear Reducers are high precision cycloidal reducers. These cycloidal reducers have unique advantages, exceptional performance, and reliability. For this reason we have chosen these gear reducers to provide our machine with the stamina to withstand severe working conditions, without any equipment breakdowns. Factory filled grease lubrication is used for its life long and formulated ability to reduce friction. Industrial quality shaft seals are used on both the input and output shafts.
The Drive Sprocket attaches to the output shaft of the gear reducer through a taper lock shaft bushing. The sprocket itself is a precision balanced component. The Idler Sprockets have precision sealed bearings.
The Drive Belt is molded to very accurate dimensions. The tensile members are made from Arimid (Kevlar) fiber. This material is stronger than steel, very light and resistant to permanent elongation. The facing is a woven treated fabric that eliminates lubrication and resists abrasion.
The Drive chains and conveyor chains are made form a unique patented design that lasts up to 7 times longer than a regular chain. The chain is a non-lubricated, maintenance free chain design, this allows for no contamination from oil coming in contact with the product.
The Way System
The Way System consists of 2 groups of parts:
· Linear Bearings
· Linear Guide Rails
These Linear Bearings are machine tool quality, offer very high load capacity, and resist moment loads in all directions. The bearings are mounted in a unique way that offers total rigidity. Integral all-round sealing is standard for all ball or roller tracks. These seals are a standard replaceable item. Food grade grease is used to lubricate the linear bearings. This product is widely available throughout the world from several different manufacturers.
The Linear Guide Rails mount on each side of the bale wrapper frame. The linear bearings run on the guide rails. Each rail is mounted so as to minimize the chance of contamination getting into the bearings.
Electrical Control
The electrical controls are housed in a NEMA 12 Control Cabinet that is climate controlled by a filtered cooling fan. The bale wrapper is controlled using an Allen-Bradley CompactLogix PLC. Ethernet and power connections are provided on the main door for PLC interface as well as a convenient fold down shelf. An Allen-Bradley PanelView Plus 1000 touch screen operator interface panel is built into the cabinet for data input, system control functions, and status output. The HMI will communicate with the Allen-Bradley CompactLogix PLC via EtherNet/IP.
Power Supply:
· Voltage: 320 - 575 VAC / 3 phase
· Power: 60 Amp
· Frequency: 50 or 60 Hz
Customer Support
Component Quality & Life - Components are industrial quality. Most components would be classified as precision to high precision. Component life usually will last well beyond the one-year warranty period. One year of life is defined as operating 24 hours a day, 365 days a year at normal accelerations and velocities.
Maintenance - The bale wrapper is designed with standard industrial components and a minimum of custom parts. Standard maintenance tools and procedures are used to work on the bale wrapper. The bale wrapper is made so that most components are easy to access.
Quality - Quality is a design choice when it comes to selecting reliable high performance components, as was done with this bale wrapper. In addition, all manufactured parts are inspected and rejected if they do not meet their specified criteria. After assembly, the bale wrapper is visually inspected and run through a test program. These tests last a minimum of 24 hours.
Support - A staff of professional machine designers, programmers, control engineers, and technicians exists to assist customers with their needs. Telephone support is available around the clock - 24 hours a day. A down machine is taken very seriously. When parts are at hand and a customer requests it, air shipping is available. Technicians, as they are available, will travel to be on-site to take care of customer requests.
Safety - SAGE bale wrappers are safe when used in compliance with the safety procedures listed in this document. A SAGE bale wrapper in its construction and in its recommended operation also complies, where applicable, with industry standards for safety such as OSHA, and ANSI.
Additional
· Bale wrapper is provided with:
· Floor plan layout in AutoCAD format;
· One set of the operator and maintenance manuals (2 Manuals);
· List of spare parts.
· Delivery - The delivery schedule is 20 weeks, after purchase order and clarification of all technical details, subject to prior sale.
