Technical Specification Machining line English 10 / 2008
Machining line
Machining line TEKNA was established in 1964 to produce efficient aluminum machining systems. The major role played by this material in the building industry has led TEKNA to develop, over the years, a vast range of products for manufacturers of window/door frames, curtain walls and coatings. The increasing use of aluminum components in the automotive and transport industries as well as in the consumer industries and in other industrial branches has encouraged the search for new solutions: TEKNA has seized this opportunity and invested into it in order to meet the new demands of the market. The experience gained in the window/door frames industry and the know-how accumulated in the field of machinery have allowed TEKNA to expand its product range including Machining lines. TEKNA has developed automatic or semi-automatic lines with systems that offer a high flexibility and can be adapted to different manufacturing contexts: from the profile cutting machines to the complete Machining lines that provide for more complex machining operations and allow to obtain, at the end of a machining cycle, a piece that is ready for the assembly stage. Over the past years we have designed several models that have been more o less customized: in fact, each supplied machining line is equipped with solutions that are specially designed based on customer s requests. Nowadays our company receives and answers to feasibility study requests every week, for this reason we can state that TEKNA is extremely qualified to provide effective responses to the most diverse problems. Thanks to the gained experience, TEKNA can offer appropriate systems for the machining and the cutting of aluminum profiles that are used in the window/door frame industry and in many other manufacturing fields.
4 Machining line The model features an automatic machining and cutting system for aluminum profiles and it is designed to minimize the manual intervention of the operator during the machining cycle, allowing the operator only to load/unload profiles. The machine can be equipped with electric-spindles (4 max) that allow to perform drilling operations on the profiles before they are cut. The machining line comprises: Loading table with a 1 axis CNC pusher Drilling unit (optional) Cutting unit Conveyor belt Thanks to the versatility of its components the model can meet the manufacturing needs of every customer: profiles clamping and machining systems can be customized according to the characteristics of the workpieces, to the working cycles and to the type of machining to be performed. The high automation of the model significantly reduces machining times while improving the production process.
Machining line
Machining line Technical features Loading table Max profiles length 6500 mm PUSHER Max displacement speed Axis X Movements axes (manual adjustments) Axis Y Axis Z Control of axes Axis X 65 m/1 150 mm 190 mm Brushless motor, truck on ball linear slideways, precision rack Drilling unit (optional) Axis run Axis Y 50 mm max Movements axes (manual adjustments) Axis Z 37 mm Electric-spindle (4 max) Collets ER 25 Max power (S1 service) 1,3 kw Max rotation speed 12000 rpm CUTTING MACHINE Max power (S6 service) 2,2 kw Max rotation speed 2800 rpm Head positioning speed 5500 deg/1 Allowed angles -45 deg to +45 deg Blade Blade shaft diameter 30 mm Blade diameter 500 mm Thickness 4,6 mm Teeth N 120 Technical data reported in the table are conditional on the systems of the machining line, therefore these data may vary depending on the chosen set-up for the different manufacturing needs. More technical data can be provided after a customized study of the machining requests of the client.
Machining line Basic machine dimensions A C B Basic machine (mm) A B C 10490 2760 1590 Weight (Kg) Basic machine 1750
8 Machining line Loading table with a 1 axis CNC pusher The loading table for the automatic movement of the profiles is complete with a structure of electrically welded steel elements that are bolted to each other; on this structure linear slide-ways with recirculating balls are mounted as well as the precision rack that allows the advance of the automatic pusher along the X axis of the machine. The pusher with 1 controlled axis (X axis) uses a pneumatic gripper to pick the workpiece from the loading table and to quickly place it near the drilling unit (optional) and then in the area of the cutting unit. Adjustments along the Y and Z axes must be performed manually. A series of idle rollers in PVC are mounted on the loading table and in addition to provide for the profile movement they protect its surface against friction or scratching.
Machining line Linear slideways with recirculating balls Linear slideways with recirculating balls facilitate the movement along the machining axes of the Machining line components (pusher). The system comprises driving ground bars and carriages equipped with scrapers and weather strips that protects from chips and dust the two internal groups of recirculating balls. These guides can stand similar traction and compression loads while keeping a low friction coefficient, a high resistance to vibrations and an optimal smoothness. These characteristics make the slideways well suited for CNC machines since they improve their high-quality performance: an efficient movement of the machine components enables a high-precision positioning.
10 Machining line Drilling unit (optional) The unit is installed at the end of the loading table, near the cutting machine, thus allowing to perform the drilling operations on the profiles before these are cut. It comprises a number of electric-spindles that are mounted in a fixed position and can be manually adjusted along the Z axis through an electronic viewer. The model can support up to 4 electric-spindles, 2 for each opposite side of the machine that are installed one in front of the other; in this way the machining processes can be executed on both sides of the profiles.
Machining line 11 Cutting unit The cutting unit is equipped with a motor-driven single-head cutting machine whose heavy structure in electrically welded frame ensures a great stability during the machining process: Its thick plates contribute to the group robust structure and minimize the vibrations during the cutting. The full enclosure achieves the noise reduction and provides a safe working environment. The cutting machines can position the head at high-speed and it is equipped with a carbide tipped circular blade of large diameter that is suitable to carry out precise cutting of aluminum profiles. The blade rotation is driven by a self-braking motor which, in addition to providing a high braking capacity, can produce a max power of 2.2 kw in S6 operation mode and a max rotation speed of 2800 rpm. The blade feed speed is adjustable and is controlled by an oleo-pneumatic cylinder.
12 Machining line The machining table of the cutting unit is customized to fulfill customer s machining needs: according to the customer s requests, it is possible to configure different systems that adapt to the various types of machined profiles. Using a centesimal electronic positioner the cutting machine head can rotate to any angle between -45 and +45.
Machining line 13 Cuts graphic 350 300 90 250-45 / 45 200 150 100 50 0 50 100 150 200 Technical data reported in the table are conditional on the systems of the Machining line, therefore these data may vary depending on the chosen set-up for the different manufacturing needs. More technical data can be provided after a customized study of the machining requests of the client.
14 Machining line Conveyor belt The CNC controlled conveyor belt is mounted at the side of the cutting machine and it is used to collect the machined profiles and then transfer them to the unloading area. Safety protection The model is equipped with a safety light barrier system that prevents the operator from accessing dangerous zones when the machine is working: the operator is allowed to access the machine only when safety conditions are met. The cutting unit is equipped with a full enclosure whose front shield is completed with an automatic lowering function to protect the operator against contact with the blade and the chips that are formed during the machining.
Software Machining line 15 Hardware The CN6 hardware is made up by two processors: A processor controls the CN6 and the other controls the functions of a common PC; thanks to this system you can use the function of the common PC even while the Machining line is working. It includes: CPU PENTIUM card Keyboard, mouse, LCD 17 color screen Ethernet card for the network connection USB and parallel ports Axis control cards Hard Disk with minimum capacity of 40 Gb Modem for the direct connection via Internet
16 Machining line Software CN6 Numerical Control The Numerical Control basic software controls all functionalities of the Machining line through an interface based on windows that includes: User graphic interface (HMI, Human Machine Interface) that displays all variables of the line (for example spindle position, tool rotation and feed, etc.) and from which it is possible to activate some auxiliary devices (such as lubrication system, chips belt, etc.) User table that combines each tool with one or more performance such as rotation speed, penetration speed or milling speed A series of table with all configuring parameters of the Machining line
Software Machining line 17 CN6 The CN6 license includes: Numerical Control management software Formulas Software Software for remote connection Formulas You can use it to define formulas based on the default variables. Remote connection This functionality allows to directly update the CN6, Maintenance and Technical Support on the machine, remotely via Internet using a telephone line (modem) or via a LAN (Ethernet card).
18 Machining line Software TK Cut List Optimizer The TK Cut List Optimizer is a program that can be used to create optimized cut lists for cutting machines. Its main functions are: Entry and editing of cut types: The user can insert and modify the cut types by specifying data as cut length, profile height, left/right cut angles, quantity, number and hole position, if any. Optimization: The optimization of the bar cut allows to minimize the production waste resulting in a substantial saving of material. Data import and export: Cut lists to be optimized are imported from a.csv (comma separated values) file. Optimized cut lists are exported in an Excel worksheet, in.xls or.xml format. Labels: machined products can be easily and quickly identified thanks to the created and printed labels.
Optional software Machining line 19 Abacus Win Cam The license of use of the Window/Door Frame Software package (for Windows OS) includes: Data file: A graphical interface assists the user in inserting technical and commercial data of profiles, accessories, glasses and panels for an unlimited number of different series. These data can relate to hinged or sliding door/window frames, shutters, partition walls, frames with folding openings and curtain walls. Types: It is possible to graphically create any window/door frame model (complete with sections and intersections). Each type can be complete with an accessory kit. Work orders: Starting from the type of product, the user can create a quote, the cut note, the optimization of the cut notes or the summary of cuts divided into profile codes and progressive measures. Quotation: The program creates printable quotations with cost estimates that can be submitted to the customer. Cutting lists: The software processes the cut lists using the optimization print function, the summary of multiple lists and a.dxf view of the profiles.
Technical Specification DATA AND GRAPHICS ON THIS CATALOGUE ARE PROVIDED MERELY FOR INFORMATION PURPOSES. TEKNA RESERVES THE RIGHT TO CHANGE THE CATALOGUE WITHOUT PREVIOUS NOTICE, FOR TECHNICAL OR COMMERCIAL PURPOSES. Machining line Branches Teknacentro Tekna Nordest TK Maquinaria TK Portuguesa TK Porto Tekna Deutschland Tekna USA South America China Via Monte Bisbino, 56 20021 Baranzate (Milan) Italy Tel. +39 02356961 Fax +39 023562293 tekna@tekna.it www.tekna.it English 10 / 2008