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

BETH Sondermaschinen GmbH
BETH Sondermaschinen GmbH

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

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