Formdeck DC 6 - Braking Resistor.

Electric Resistor Brake – this item was not fitted.
There was no brake system on the De-coiler machine to slow down or stop the coil. 
 We harvested a brake resistor from a spare control cabinet and wired it up. After setting the speed controller most of the problem went away. 

This is a DC Brake Resistor - not fitted to control system.

DC Brake Resistor in a similar machine.

Close-up view of the Resistor value.

Formdeck RM 6 - Control Switch.

De-coiler Stop / Start switch broken – this has happened a number of times because of the harsh environment on the floor where the switch operates. 

Proxy sensor switch in the center of the two rollers has no influence on the machine operation.

The micro switch mounted on an angle is what starts / stops the machine.

This has been replaced twice and seems to last when placed on the angle seen in the photo.

Ulimately this set-up should be discarded and replaced with the system below.

This has proved to be the most reliable and maintenance free option fitted to other machines.

Here is the complete option.

Formdeck - DC 6 Transmission Failure.

Cycloidal Transmission has broken right off it's mounting pedestals.

A closer look.

 Drive sprocket on the main shaft is much to small / ratio is poor for this application.

Destroyed transmission removed. 3.5 Ton coil of steel this set-up has to deal with is still in place.

New electric motor and transmission ready for assembly.

New base plate being fabricated for transmission and electric motor.

Motor and transmission assembly on it's way into the mill.