In modern manufacturing, particularly in the fields of metal processing and long product forming, continuous and efficient production is key to determining the performance and cost of the production line. To ensure uninterrupted operation and improve production efficiency, storage systems have become an indispensable technical support. Today, we introduce two common storage systems—horizontal accumulators and rolling accumulators—and how they play a crucial role in production lines through their complementary functions.
As the name suggests, a horizontal accumulator is a device used to temporarily store excess material on a horizontal plane during production. Its main task is to alleviate the instability of material flow and avoid production stoppages due to equipment roll changes, failures, or temporary shutdowns, all without affecting the operation of the main production line (such as forming machines, welding machines, etc.).
A horizontal accumulator typically consists of multiple guide rollers and horizontal storage tanks. Materials are fed into the storage tank through the guide roller system and looped serpentine across a long path. In this way, the storage tank can store a large amount of material, providing a buffer for upstream equipment and ensuring a stable supply of materials to upstream equipment.
Between decoilers and forming machines
Mitigates speed differences between the two, ensuring stable operation of the forming machine.
Welded pipe production lines
Horizontal accumulators can effectively buffer various processes on the pipe welding lines, preventing material accumulation or breakage due to speed mismatches.
High-frequency welded pipe lines and cold roll forming lines
In these scenarios requiring high-speed continuous processing, horizontal accumulators provide essential intermediate buffering.
A rolling accumulator, also known as a drum accumulator, is a device used to store materials by rolling them along a certain trajectory. It typically involves multiple drums or roller conveyors. Materials roll on these conveyor rollers, forming a cyclically flowing storage area. Compared to horizontal accumulators, rolling accumulators focus more on the rolling motion of materials and automated adjustments, allowing for more precise control of storage volume and flow speed.
The working principle of a rolling accumulator usually involves guiding materials on a dynamic, continuous track using multiple drums, guide rollers, or similar devices. As materials flow, the amount of material in the accumulator automatically adjusts according to actual production needs and automatically supplements based on equipment speed changes.
Roll forming production lines
Rolling accumulators are often used to control the storage of strip steel in forming lines, especially when the strip steel needs to be switched from multiple reels.
High-speed production lines
In high-speed production lines such as pipe welding lines and high-speed rolling mills, rolling accumulators ensure that the main equipment can maintain continuous operation through their flexible storage and release methods.
Multi-station production lines
Rolling accumulators are usually equipped with automatic sensing and control systems, which can adjust the storage volume according to the speed of each station on the production line to avoid material stagnation or breakage.
In many industrial applications, horizontal accumulators and rolling accumulators can be used in combination to better meet the needs of the production line. Their combination can often stabilize material supply while reducing production interruptions and waste.
Horizontal accumulators provide a buffer area that matches the speed differences of upstream equipment, preventing production interruptions due to unexpected situations.
Rolling accumulators dynamically adjust the material supply to respond to changes in production line speed through their dynamic storage method.
In high-efficiency production lines, horizontal accumulators can handle large amounts of strip steel storage requirements, while rolling accumulators are more suitable for fast and efficient material supplementation.
When used in combination, the two can be controlled in coordination to provide a larger storage pool, ensuring uninterrupted operation of the production line.
Both are usually equipped with advanced PLC control systems that automatically adjust storage volume and speed according to production needs. The system monitors material flow in real time and dynamically manages storage to maximize production efficiency.
By combining the use of horizontal accumulators and rolling accumulators, production lines can achieve stable material supply, improve overall production efficiency and product quality. With the continuous advancement of intelligent control systems and their increased automation, these storage systems become more precise and efficient, thereby making the entire production process smoother, more energy-efficient, and economical. Whether in pipe welding lines, cold roll forming lines, metal stamping, or high-frequency welding and other high-speed production lines, reasonably configuring storage equipment to maximize space utilization and increase automation levels will be a goal that manufacturing continues to pursue in the future.
