High-speed production of window fittings
Whether frames, fittings, back panel housings or soft-close units - many products in fittings technology are manufactured with solutions from PIA. The automation specialist has now developed a new assembly and testing line for a manufacturer of window fittings.
Opening, tilting, closing and locking: Window fittings ensure that a modern tilt and turn window fulfills its mechanical functions. The hardware should also protect against break-ins, be durable and easy to operate. But what criteria must an assembly and testing system for such window hardware meet? “Our customer had clear requirements for the system. Among other things, he wanted high performance, a robust design, high system autonomy, short cycle times for different variants and minimal set-up effort,” explains Harald Mais, Key Account Manager at PIA Automation.
Efficient and flexible production
The system developed by PIA meets all these requirements. It consists of six interlinked assembly modules, each of which has an intermediate buffer. These buffers ensure a continuous production flow and prevent bottlenecks. The production line picks up the individual parts using 25 component feeders. Particularly outstanding are the three specially developed set-up long part feeders. With their technical assistance, the system can process up to 40 long parts per minute with a product length of 600 to 1000 mm. Automatic position detection and the ejection of incorrectly oriented parts during operation ensure a smooth production process
Easy maintenance of the riveting stations
The line has 34 riveting stations. They are modular and can be removed for maintenance. This simplifies maintenance and minimizes downtime. Another benefit for the customer: The machine can be modularly and largely automatically modified to 27 variants with component lengths from 300 to 1000 mm. This flexibility allows quick adaptation to different production requirements.
Innovative carrier concept
Another highlight is the innovative, freely positional pick-up concept. It enables flexible and precise handling of the components, which significantly increases the efficiency and quality of production. The system is controlled via an ultra-compact BECKHOFF industrial PC. With its extreme computing power, it is ideally suited for complex applications and motion applications.
Convincing performance data
With more than 50 assembly stations, the system achieves an impressive output of 34 parts per minute, far exceeding the customer's expectations. The assembly line integrates many core processes that have been specially developed for the requirements of fittings technology:
- Handling of long parts: This in-house solution from PIA enables precise and efficient handling of long components.
- Radial riveting: Stations can be pulled out for easy maintenance.
- Robot-assisted assembly: The scissor link and scissor arm are assembled and connected using a 6-axis robot.
- Testing and inspection: The system carries out comprehensive clamping force tests and various assembly checks.
“The development of our new assembly and testing line for window fittings was a complete success. With innovative concepts and modern technology, our development team has created a solution that is not only efficient and flexible, but also meets the highest quality standards,” says Harald Mais, Key Account Manager at PIA Automation.
