Drive System Motion Control And Electric Cylinders Replace Manual Process Steps

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Beckhoff Automation GmbH & Co. KG

FAULHABER Drive Systems

Wuxi InfiMotion Technology Co., Ltd.

With a unique machine concept, CNC Solutions and Calvet are automating previously manual processes in the production of aluminum windows and doors. High-performance drive technology, motion control, and Beckhoff's AA3000 electric cylinders provide the machine with the necessary "finesse" for pressing window frames.

The mechanical engineering company Calvet N.V. in Zellik, Belgium, aimed to further automate various processes in window and door production with a new machine concept. "Together with CNC Solutions, a machine builder specializing in custom plants like Calvet, and the experts from Beckhoff, we were able to realize the ambitious concept," emphasizes Stefan Nees, Managing Director of Calvet. "We were able to contribute with our expertise in CNC and robotic applications," adds Lander Debruyne, Managing Director of CNC Solutions BV in Menen, Belgium.

With the automated process, we set the bar significantly higher in terms of quality and greatly increase efficiency in window production.

Stefan Nees, Managing Director of Calvet

Quality And Productivity Boost in Window Construction

Until now, the aluminum profiles of a window were joined together in so-called corner presses. This process still requires several manual steps beforehand, demanding a great deal of precision from the production worker to ensure the quality of the window or door frame. "We have consolidated and automated these manual steps—assembling, gluing, pressing, inspecting, and even polishing—at a central workstation," explains Stefan Nees.

In the future, the operator will place the profiles of a window frame on a cart. Sensors will check whether the correct parts have been inserted and whether they fit together. Only then will the profiles be positioned, clamped using brackets, and subsequently pressed together with the required force. "With the automated process, we are raising the bar significantly in terms of quality and greatly increasing efficiency in window production."

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Three Electric Cylinders form A Gripper

In addition to quality and productivity, flexibility was also a top priority in the machine's specifications. After all, there are numerous profile types, pressing positions, and bonding techniques. As a result, two 6-axis robots form the core of the installation. Depending on the window size to be produced, which ranges from 12 to 177 inches, they are positioned and automatically pick up the appropriate tool for the specific production step. "What makes it unique is our special gripper for pressing the corners together," highlights Lander Debruyne.

The basis of a gripper consists of three AA3000 electric cylinders with spindle drives. "By evaluating the currents and torques of these drives, we were able to give the machine a sense of the contact pressure and regulate it dynamically," says Stefan Nees.

Our Application Engineers Support the Transition And Ensure a smooth start or assist existing customers in implementing new technologies.

Cédric Sabbe, Account Manager Beckhoff Belgium

Seven Machines With PC-Based Control in Use

It is no coincidence that CNC Solutions uses PC-based control and other components from Beckhoff in the machine. Lander Debruyne explains: "About two years ago, we switched to the Beckhoff platform and Embedded-PCs CX2043 as standard controllers because we were constantly experiencing availability issues with our supplier at the time."

Additionally, CNC Solutions routinely uses Stäubli robots, which can be integrated and controlled efficiently via EtherCAT and Unival Drive. "Changing control technology is not something you accomplish overnight," explains Lander Debruyne, "but with application engineer Maarten Knevels, we always had an absolute expert by our side whenever needed." Meanwhile, seven machines with PC-based control are already in use by customers. "Our application engineers assist with the transition and ensure a smooth start or help existing customers implement new technologies," adds Cédric Sabbe, Account Manager at Beckhoff Belgium.

In addition to the robots, 15 CNC axes (AM8000 servo motors and AA3000 electric cylinders) are controlled via TwinCAT 3 and the AX8000 multi-axis servo system. Alongside EtherCAT terminals, Calvet and CNC Solutions utilize numerous EtherCAT Box modules with IP67 protection to read signals and operate the actuators directly mounted on the carriages. Cédric Sabbe adds: "The compact drive system and the OCT connection technology of the servo motors enabled space-saving and rapid installation."

Robots, CNC, And Motion Control Flexibly Combined

"Perfectly coordinating all processes was the challenge in this project," says Stefan Nees.

• The complex coordination of all axes was solved with TwinCAT 3 NC PTP, NC I, and CNC.
• Via a Control Panel CP2918, the operator receives instructions for setting up a job and can monitor the processes in the machine.
• The order data is loaded from the central order management via a barcode on the window profiles.
• The necessary connectivity with the barcode scanner and IT is implemented by Calvet using TwinCAT 3 Serial Communication (TF6340) and TwinCAT 3 Database Server (TF6420).

"To keep operation as simple as possible, there are only two buttons that allow the operator to navigate to the next or previous work step," explains Stefan Nees. It couldn't be simpler.

The first system has been installed at a window manufacturer in Brussels to comprehensively test the machine in the field. "Feedback from practical use will help us develop the prototype into a high-performance series machine," concludes Stefan Nees.

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