Processing Line for Aluminum Extrusions

Aluminum extrusion 1The project was a request to develop a proposal for a fully automatic machine line for fabrication of aluminum extrusions. The existing basis was an old slissemaskin with rotating blades with an hydraulic drive that was worn out. All the input and output function of the machine took place manually. This was a demanding job as due to the used profiles being large and heavy. An existing machine for stretching profiles may be integrated in the line and controlled from a remote pls.
The first part of the new line comprises of a lifting portal, turning board, and feeding table to the slissemaskin. Untreated profiles are loaded by forklift into fetch positions so that the operator can avoid heavy lifting. Profiles are retrieved by portal from retrieving position with a gripper mounted and delivered to the slissemaskin innbord where the profile is pushed into the machine. It can be used as both a vacuum gripper and a grapple depending on the profile type.

A new slissemaskin was constructed with the electric drive of the knife rollers. On the knife roller was a 33kW motor with a 57x exchange gear so that powers are formidable on the knife. The machine was sized accordingly and weighed 5 tons by itself!

Fact sheet:

  • WinCC flexible RT HMI
  • Siemens S7 PLC
  • Siemens G120 inverters
  • NORD gearmotors
  • 4 Festo servo axes for lifting portals
  • 6 Festo servo axes for positioning
  • 3 Festo CPX valve terminals
  • 3 Beckhoff IO nodes
  • SiC i52 pinmarker
  • 3 IO boards via Profibus
  • LINAK linear actuators
  • Light curtain and Emergency Stop via ASi bus

» Download datasheet

The next part of the line is a transfer table with side displacements of profiles and a feed to the stretch bench. This machine is integrated into the line so that untreated profiles could be pushed into the machine. Prescription data and start signals are loaded into the stretch bench profile, stretched, and the finished profile retrieved. On the way out, the profile is marked with batch numbers for traceability in production. After this, the profile is obtained by new lifting portal stacks profiles on the trolley going into the curing oven. All process data is stored in the prescription system in HMI so that the operator can easily adapt the machine for different products. Necessary driving data is automatically downloaded to the servo drives so that the machine sets itself to the correct position. Dynamic points are continuously calculated pls and sent to servo controllers via Profibus.

Retrieving and stacking sequences are programmed in a sequence editor in PLC. All parts of the machine run asynchronously when the next seat is available, starting the process of processing products to this space. This reduces cycle time, makes programming easy, and provides the operator with a good overview of the machine and operation.