Using Automation
to achieve 3.3 doors/Minute
High quantities mean high consumption values and high personnel costs, right? Not in this project. Our customer, a well-known door manufacturer from the Netherlands, has taken the next step and modernized its production with us. In addition to a wide variety of machining operations and various assemblies on both the lock and hinge sides, all processes in this system are meaningfully linked by automation. Entirely without any cost-intensive interfaces between individual machines, the doors in our turnkey solution are detected, processed, assembled, cleaned, engraved and finally even palletized on an order basis depending on the type - and all of this at a cycle rate of up to 3.3 doors per minute!
At the same time, the sustainable and cost-optimized production was the focus of the concept. Thanks to the targeted selection of special drive systems, the door production machine now impresses with particularly low air & power consumption values, which are additionally supported by energy recovery mechanisms. Personnel costs are another point of long-term cost optimization: This shows once again that the devil is often in the details. Skillful automation has enabled time- and resource-intensive secondary processes, such as protective board handling, to be optimized and staff utilization to be significantly reduced. The door production line is rounded off by state-of-the-art control technology with parts traceability, linked to the customer's master computer system.
The process steps
- At the beginning, the different door leaves are fed in stacks.
- The door stacks are identified via a scanner.
- The doors are then fed into the line via a robot, which simultaneously also performs a plausibility check.
- As soon as all the doors in a stack have been removed, a smart secondary process automatically conveys the protective boards to the end of the line.
- Depending on the door leaf type, hinge drilling is performed in the first door processing machine, and hinges are also mounted directly afterwards. The material is fed automatically.
- In the next machine in the line, hinge milling is possible, such as tab hinges, Tectus hinges, etc.
- Directly afterwards, the side edges of the hinge side are cleaned.
- Automatic laser engraving of barcodes or DMCs can then take place in a special device. In this application, the customer logo was engraved.
- Even before engraving, the respective door is automatically rotated on a door turning station.
- The third machine in the line now performs forend, door handle and/or key milling on the lock side, as well as pre-drilling and rosette drilling.
- This is followed by various lock case milling operations at another station.
- With the help of the automatic tool change system, a wide range of tool lengths and diameters can be used.
- This is followed by cleaning of the upper and lower surfaces and the lock case using brushing, vibrating and vacuum technologies.
- The next process step involves the lock assembly with robot-controlled feeding from magazine units and automated bolting, with the magazine shafts being filled by bunker feed units.
- Of course, all machines with noise-intensive machining operations are equipped with a soundproof enclosure.
- At the end of the line, two robots take care of the order-based palletizing onto the protective boards. This prevents surface damage.
Facts
- Doors weighing up to 100 kg can be processed thanks to the robust design
- Smallest dimensions of the doors: Length x width x depth: 1500 mm x 300 mm x 30 mm
- Largest dimensions of the doors: Length x width x depth: 2700 mm x 1500 mm x 80 mm
- Cycle rate depending on the machining content of up to 3.3 doors per minute
- Increasing the machining supports for high accuracy standards
- Space-saving design adapted to the customer’s production environment
- Intelligent setup for flexible access to different machine areas to allow for easy cleaning and maintenance
System animation
Distinctive features of the project
- Consistent parts tracking throughout the process
- Durability due to solid construction and proven designs
- Large number of machining and assembly steps implemented in a space-saving manner
- Use of clockwise and counterclockwise milling motors for maximum quality
- Exclusive use of known components for fast service availability
- High, but at the same time individually adjusted degree of automation, adapted to the customer's requirements
- Flexible control options between individual assembly steps
- Drilling unit with individually selectable drilling spindles
- Hinge screw-in unit, including 8-fold magazine for different screw-in hinges
- Significant reduction in ongoing production costs
Additional information
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VIDEO: Automated door production
Are you interested in a similar project in the field of automated door production? Then you should definitely watch our project video: Thanks to state-of-the-art automation, different types of doors - whether non-rebated or rebated - can be processed and assembled regardless of their respective dimensions.
Tailor-Made Automation
We think automating is interesting for companies of all sizes and offers huge potential along the entire production chain. We give you a custom concept with the optimal degree of automation for you, adapted to your individual requirements.
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