The equipments required for production of PVC windows and door

Things you need to know about windows and door production
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Machine selection: principal factors
It is not possible to realise windows production from PVC profile without a special machine park. For this reason, it is necessary first to mention the final target where production will be arranged in order to approach the issue of equipments.
When we look from the perspective of production dimension while leaving the economic dimension aside, there is one single target - to produce window. Window is comprised of four main components:
PVC profile elements (strongbox, wing, central record, lath)
Support sheet profile (added into strongbox, wing and central record)
Accessories (hinge, arm, espagnolette, etc.)
Thermopane (heat isolator)
Since Thermopane production is a comprehensive issue on its own, we do not examine it here in this article. Generally, a large majority of newly developing window producers are giving orders to privatised companies regarding isicam.
The equipments required for production of PVC windows, are basically determined from among the factors below:
Amount of production made
PVC profile series number
Production in small, average and big volumes in capacity can be defined as 25-35 products, 50-60 products and 80-90 products per shift in standard. 120-150 product capacity level can be reached with the application of automated production complexes. Now, let us examine where the stated figure classification came from.
The factor most determinant in the production capacity is the welding machine, because only the production cycle of this machine is linked with fixed timing (profile placement, heating, welding and weld cooling procedures), production cycle time are dependent on the characteristics of PVC and they vary only slightly. Time spent for the completion of cycle are dependent on the characteristics of PVC and they vary slightly. Cycle period is accepted as approximately 3 minutes. This cycle is the same for any type of welding machine as single corner, double corner and four corner. In fact, single corner welding machine merges 20 corners per hour, double corner welding machine - 40 corners, four corner welding machine - 80 corners through welding. Windows, can be in a different type as known: blind window is comprised of 4 corners; single wing window is comprised of 8 corners, 4 on this strongbox, 4 on the wings; double wing window is comprised of 12 corners as strongbox and two wings. Therefore, welding time of two wing windows is equal to three blind windows. As the orders could be different in the determination of atelier capacity, they are accepted as statistical average product. On the basis of capacity calculation results above and depending on the welding machine model, it is possible to propose different alternatives in atelier establishment.
Standard atelier equipment set
General equipments:
PVC profile cutting machine
Support sheet profile cutting machine
Water discharge machine
Triple drill copy milling machine (for opening of door arm slots, hinge and spagnolette channels, etc.)
PVC profile welding machine
Corner cleaning machine
End milling machine
Glazing beat saw
Additional equipments:
Hand tools (screw, drilling machine, etc.)
Operational (assembly) tables
Shelves and carriers for transport of raw materials, semi-finished products and ready-made products inside atelier
Thermopane placement stand
Accessory assembly station
Compressor with air cleansing and drying system
Which factors should be taken into consideration in the formation of equipment set?
In minimum atelier alternatives, single head cutting machine and single corner welding machine are available. Double corner welding and double head cutting machines are also used to increase atelier production. Double corner welding and double head cutting machines are also used to increase atelier production. It is useful to state that the work perfection will increase in case of utilisation of double head machines. Cutting machine completes single cycle procedure in single cycle and welding machine merges three pieces concurrently by welding. This, significantly decreases possibility of an error share in product adjustment.
Machine general characteristics which should be considered in the selection of equipments and that we have are as follows:
All our machines are produced on the basis of full work security.
Compatible with CE Machine Security 98/37/EC and Low Voltage 73/23/EC instructions.
GOST and UkrSepro certified.
Electro-pneumatic controlled which is a rather important characteristic for each machine.
PVC piece cutting
In double head and single head cutting machine of profiles, cutting is made with an angle of 90° - 20° and upto 4000 mm depending on the model of cutting machine. PVC piece cutting is made according to 5-6 mm welding gap (welding tolerance is a parameter associated with welding machine settings and it could be within the limits of 2,5 - 3 mm per side). Strongbox and weld profiles are cut with an angle of 45°. Central record is cut with an angle of 90° depending on the amount of tolerance on each corner to be 2,5 - 6 mm per each side (milling machine settings are taken into consideration).
Support sheet cutting
Depending on material flexibility parameter of window profiles, steel sheet profile with zinc is placed between PVC. Support sheet cutting procedure are applied on single head cutting machines in different power levels. Support sheet profile cut off for strongbox and wing should have a length of 10 mm less than the PVC profile in which it is placed. Thus, a distance of 5 mm is provided on each corner of window profile for the making and merging of parts on sides of window profile. Since central record profile is placed with mechanic connections, it is cut of 15 mm less than the length of support sheet profile.
Profile welding procedure
Welding procedure is carried out by means of special machines. Welding machines are classified as single, double and four corner welding machines. Production at the highest level is provided with four corner welding machine; welding process of a product is completed in single cycle. This process is completed respectively in two cycles in double corner welding machines, in four cycles in single corner welding machines. As we mentioned earlier total production is closely related with the welding machine model and the selection of this machine depends on the productivity of atelier.
Corner cleansing procedure
Corner cleansing procedure of parts is made either by hand or by means of special machinery. A sharp end cutter or a special blade in the form half-moon is used during hand cleansing procedure. In order to avoid a damage arising from blades in the automatic corner cleansing procedure it is necessary to pay attention to front surfaces of PVC profiles. Automatic ccorner cleaning machine has the characteristic to protects upper and lower surfaces as well as outer corners. After completion of corner cleansing and quality control procedures, parts are placed on special shelves where intermediary products are located.
Central record matching procedure
This procedure can be performed either manually or by means of a machine having one or two milling blades in the form of automatic milling. Selection principle is logically related with the selection principle of ccorner cleaning machine.
Lath cutting procedure
Lath cutting procedure is realised in lath cutting machines with an angle of 45°. The structure of machine displays the feature to cut two lathes at the same time and removes any unnecessary procedure. A set of machine is inclusive of right and left conveyor measurement system. The feet of lathe ends are cut of at an angle of 45° from opposite directions under normal conditions. With the help of combination saw system, lath is cut off concurrently both normally (forward) and from below. Depending on sliding balls, strongbox or wing welding connection points do not constitute any obstacle for the placement of lath. In case of placement of a gasket in factory, cutting of gasket is made together with the lath. In the event of lath being used without a gasket, lath is cut off first, then the gasket is placed in the lath for glass and pliers are cut off according to their full size. During placement of lathes cut off at an angle of 45°, first short and then long lathes are placed. Lathes are mounted in their place with soft strikes with the help of a plastic or rubber hammer. If glasses are required to be mounted on window, lath is removed with the help of a sharp pointed spatula.
Opening of water discharge channels
Special water discharge holes are opened from different strongboxes for water discharge and strongbox / wing ventilation inner surfaces in sizes of 5x20 mm minimum in a way not to have less than 60 cm between two holes. All visible outer surface water discharge holes are closed with special plugs. So, inward flow of water from outer surface is prevented. Water discharge machines are classified as single, double and triple. The most frequently used among them is triple water discharge milling machine. In this machine, strongbox wing and intermediary wing is processed without any need to be implemented again. This procedure could be performed with double water discharge machine as well, but a re-adjustment at a very low level is needed. In case of increases of productivity, differentiating the processes of strongbox, wing or intermediary wing processing is an effective method.
Central record matching milling procedure
Milling procedure of double corners of profile intermediary wing in double corner is dependent on the form of integrated profile. End milling machines used in such procedures, differ according to part squeezing and manual / automation characteristics.