How to Choose Servo Roll Feeder?

In roll forming applications, servo feeders are typically used in pre-notching or pre-cutting operations. However, there are a few options for roll formers when it comes to feeding coil for these operations, so There are a few things to consider when you’re considering a servo feeder. In this post, we'll discuss the basics elements you need to know when deciding if adding a servo feeder is right for your operation and then selecting the one that’s right for you. 

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When to Use a Servo Feeder

Servo feeders are ultimately replacements for mechanical feeders, gripper feeders, and other machinery of that nature. The more manual and mechanical the feeding equipment, the more chance for marring the material during transfer by the operator or maintenance personnel, and precision in feed length is very difficult to dial in.

A gripper feed is not ideal for applications where you need to avoid scratching or marring on the material. A gripper pinches and drags the material, then lets go and rotates back to position. In contrast, a servo feeder is a simpler, more accurate way to convey material from point A to point B. Its feed length can be adjusted while the machine is running, which most feeding equipment can't do.

We often talk about roll repeatability as a measure of unit accuracy. The distinction is on the accuracy of the unit is plus or minus two thousands. If you were describe a line on your upper and bottom pin roll, you put in a specific feed length, those based on the circumference of the rolls, then you should have those two points meet back up after a full rotation. On a gripper style or cam style, there’s no way to achieve that level of accuracy.

Choosing the Right Servo Feeder for You

In short, the main elements you want to consider when choosing a servo feeder include the size of the unit, the material thickness, the line speed, feed progressions or feed lengths. These considerations will allow you and your supplier to size the motors and the roll diameters for your specific needs. 

You could choose a two roll or a four roll servo feed depending on your application. A four roll feed has twice the amount of surface contact with half the amount of air pressure, thereby decreasing the chances of scratching or damaging the surface critical material you’re feeding into a roll former or a press. Meanwhile, a two roll machine will use more air pressure. A four roll servo feeder can also be more precise because it does decrease the chance for slippage by design. However, accuracy in terms of roll repeatability is the same for two and four roll models.

You will also want to consider if your servo feeder is a standalone cabinet or mounted to the press. While some presses may not have the ability to have the servo mounted, this may be up to your preference in many cases. The biggest advantage of having a standalone unit is you’re not subject to any vibration from the press itself, which could lead to miss feeds or inconsistent feed lengths. Mounted units may also present issues with accessibility to the press window. Most customers nowadays opt for a cabinet mounted unit that is not subject to those vibrations. In both cases, you may consider allowing for adjustability of those units, so you could adjust your pass line height.

Want to learn more about choosing the right servo feeder with the features you need?

When it comes to selecting the right feeder for industrial applications, customers often encounter a range of options, including air feeders, roller feeders, and NC servo feeders. Among these, the NC servo feeder stands out for its ease of use, high precision, low failure rates, and ability to integrate the benefits of air and roller feeders. However, choosing the right NC servo feeder can be challenging due to significant price variations among manufacturers. To ensure you invest in a high-quality NC servo feeder at a fair price, it’s essential to evaluate four critical aspects: process requirements, mechanical specifications, manufacturer reliability, and after-sales support.

1. Understanding Process Requirements

Material Thickness and Compatibility

One of the most important factors to consider is the thickness of the material you’ll be feeding. NC feeders are typically categorized into three types based on material thickness:

1. Thin plates (0–2.2mm)
2. Medium plates (0–3.2mm)
3. Thick plates (0–4.5mm)

Generally, the thicker the material, the higher the cost of the feeder.

Speed and Relaxation Type

Your production speed and compatibility requirements also play a crucial role in choosing between mechanical and pneumatic relaxation systems:

• Pneumatic Relaxation: Ideal for general applications, this type uses a cylinder to control roller compression and relaxation. It’s versatile and works well with punch presses and shearing machines but may be slower for high-speed operations.
• Mechanical Relaxation: This system employs a lever arm to control rollers and is suited for short-step, high-speed feeding. While it offers better speed and reliability, it’s more expensive and works only with specific machines.

Servo Motor and PLC Quality

The feeder’s precision and stability depend heavily on its servo motor and PLC (Programmable Logic Controller). Top brands like Mitsubishi, Yaskawa, and Panasonic are highly recommended. Among them, Yaskawa servo motors combined with Mitsubishi PLCs provide exceptional performance and reliability.

End-of-Material Detection

To protect your molds and equipment, opt for an NC feeder equipped with an end-of-material detection system. This feature automatically halts the feeder when the material runs low, preventing potential damage.

Human-Machine Interface (HMI)

Modern NC feeders come with various control options, including button-type interfaces, 3.2-inch touchscreens, and advanced 7-inch touchscreens. Popular brands like Weintek (Taiwan) and Mitsubishi (Japan) offer durable and user-friendly HMIs. Choose based on your operational needs and budget.

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Aesthetic and Structural Design

The machine’s design and finish should adhere to industry standards, reflecting quality craftsmanship and durability.

2. Evaluating Mechanical Requirements

Roller Material and Durability

Rollers are critical components in an NC servo feeder. Ensure they are made from imported bearing steel, hardened to HRC60 or higher, and finished with hard chrome plating and precision grinding. Other components should meet or exceed Q235 material standards.

Assembly and Structural Integrity

High-quality assembly is vital for smooth operation. Key points to check include:

• Perfect alignment of component edges.
• Smooth and uniform contact between rollers and wall plates.
• Lightweight hollow rollers for better feeding precision.

Welding Standards

Ensure the machine body adheres to standard welding practices. Welds should be smooth, firm, and free of weak spots or defects.

Testing and Quality Assurance

Comprehensive testing is essential to verify the feeder’s performance. Key tests include:

• X-axis parallelism: ≤0.01/200
• Upper roller runout: ≤0.005
• Roller cylindricity: ≤0.002

Additionally, conduct vibration, temperature, and stability tests to ensure the feeder meets operational requirements. Only feeders that pass these rigorous inspections should be considered.

Component Lifespan

Opt for feeders equipped with durable bearings and motors rated for at least 100,000 hours of operation. Control buttons and other wear-prone parts should also meet lifecycle standards.

3. Assessing Manufacturer Strength

A reliable manufacturer is the cornerstone of a high-quality NC servo feeder. Look for companies with:

• Proven track records in producing industrial-grade feeders.
• Stringent quality control measures.
• Positive customer reviews and industry certifications.

A strong manufacturer not only ensures product quality but also provides better support throughout the machine’s lifecycle.

4. Ensuring Reliable After-Sales Service

After-sales support is an often-overlooked aspect of purchasing industrial equipment. A good service package includes:

• Prompt assistance for troubleshooting.
• Availability of replacement parts.
• Regular maintenance support to prolong machine life and ensure optimal performance.

Investing in a feeder with dependable after-sales service can save you time, money, and operational downtime in the long run.

Conclusion

Selecting the right NC servo feeder requires careful consideration of process requirements, mechanical specifications, manufacturer reliability, and after-sales service. By evaluating these critical factors, you can confidently invest in a feeder that meets your production needs, enhances efficiency, and provides long-term value.

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