Specialized machine for applying insulation tape to round stainless steel housings

Solution description

The machine base is constructed from MiniTec aluminum profiles using PowerLock connectors. Profiles measuring 90x90, 45x90, and 45x45 are used. Direct safety in the lower section is ensured by powder-coated sheet metal panels, while the upper section features transparent polycarbonate. The area where the operator accesses the machine is protected by safety light curtains.

The machine is divided into left and right sides, which perform the same operations but operate independently. By selecting the drum type on the HMI interface, the machine automatically adjusts the drum mounting point, the position of the insulation strips, and the position of the line laser, which indicates the starting position of the insulation strip.

The machine operates in the following steps: 

1. Drum type selection: The operator selects the drum type on the control screen before the automatic operation begins,

2. Manual drum insertion: The operator manually inserts the drum into the mounting position of workstation 1 or 2 and confirms the drum’s presence by pressing the control button,

3. Automatic alignment and positioning of the drum: The machine allows insulation to be applied to two different types of drums; depending on the selected drum type, the drive wheels align and position themselves to the exact width selected by the operator.  

4. Insulation Installation: The winding arm lowers; the operator inserts the insulation strips into the guides, positions the insulation with the start of the strip on the drum, and partially unrolls the silicone backing paper of the insulation. The system then automatically winds the insulation around the drum and winds the silicone backing paper.

5. End of cycle: Once winding is complete, the winding arm is raised, and the operator removes the processed drum.

Specialized machine for installing drum insulation

Benefits of Implementing the Solution

- Application precision – We ensure precise positioning of insulation tapes,

- Optimized workflow – A fast and smooth production process,

- Reduction of errors – Minimization of human errors in production,

- Increased productivity – Significant improvement in production capacity,

- Improved safety – Ergonomic design for a safe working environment

The entire process is repeatable, efficient, and tailored to standardized production requirements. 

Key technological components

• Winding system with two workstations

The machine is equipped with two workstations for winding insulation, enabling continuous production—while winding is taking place at one station, the next drum is being prepared at the other. This design reduces production cycle time and increases productivity. 

• Drum drive

The drum is driven by drive wheels powered by a servo motor with a gearbox. The wheels are interconnected via a chain drive, enabling synchronized and stable rotation for uniform and precise insulation application. 

• Drum Alignment

Before winding begins, the machine locks the drum using driven wheels powered by a servo cylinder. This ensures stability and secure fixation of the drum prior to processing. 

• Push unit

The push unit stabilizes the drum in the working position; using pneumatic actuators and a pressure roller, it ensures uniform pressure on the insulation, enabling reliable and precise application of the insulation without unnecessary air pockets beneath it. 

Our drum insulation installation solution offers a technologically advanced and efficient solution for modern production facilities where quality and productivity are of the utmost importance. With the integration of smart control units, precise sensors, and stable mechanisms, the device is suitable for automated or semi-automated lines where fast and repeatable operation is required without compromising on quality.