Assembly and testing system for hardware technology
PIA fact check
- High speed with long parts
- Flexible mounting
- Easy to maintain thanks to drawer stations
High-speed production of window fittings
Whether frames, fittings, back panel housings, or soft-close units - many products in fitting technology are manufactured with solutions by PIA. The automation specialist has developed a new assembly and testing line for a manufacturer of window fittings.
Open, tilt, close, and lock: Window hardware ensures that a modern tilt and turn window fulfills its mechanical functions. The hardware should also prevent burglaries, 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, a high level of 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 a buffer. These buffers ensure a continuous production flow and prevent bottlenecks. The production line picks up the individual parts using 25 component feeders. Particularly interesting are the three specially developed set-up long part feeders. With their help, 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 components during operation ensure a smooth production process
Simple maintenance of the riveting stations
The system has 34 riveting stations. They have a modular design and can be removed for maintenance purposes. This makes maintenance easier and minimizes downtime. Another advantage for the customer: The machine can be adjusted module by module and almost automatically to 27 variants with component lengths from 300 to 1000 mm. These flexibility enables rapid adaptation to different production requirements.
Innovative recording concept
Another highlight is the innovative, freely positionable 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 processing power, it is ideally suited for complex applications and motion applications.
Convincing performance data
With over 50 assembly stations, the line achieves an impressive output of 34 parts per minute, far exceeding the customer's expectations. The production line integrates a large number of core processes that have been specially developed for the requirements of window fittings technology:
- Handling of long parts: This in-house development from PIA allows precise and efficient handling of long components.
- Radial rivets: The stations can be pulled out for maintenance purposes, which makes servicing easier.
- Robot-assisted assembly: The scissor link and scissor arm are assembled and connected using a six-axis robot.
- Testing and inspection: The system carries out comprehensive tests of the clamping forces and various assembly checks.
"The development of our new assembly and testing system 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."
Harald Mais, Key Account Manager
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