Reynaers introduces latest technology in quality testing and production of insulated aluminum profiles
Duffel, February 2015 - Reynaers, the leading European provider of sustainable architectural aluminium solutions, proudly announces two major investments that will help them sustain their leadership. This announcement confirms the company’s belief in investing in hi-tech quality testing and insulation technology to improve accuracy, quality and production efficiency.
Testing in 3D
An advanced 3D scanner, the new Coordinate Measuring Machine (CCM), was added to Reynaers’ recently refurbished quality testing laboratory (Q Lab) were Reynaers test the strength of profiles, layer thickness, gloss and adhesion of lacquers, performance of support gear, dimensions, scratch measurements, hardness of aluminium, etc.
For the first time, a scanner of this kind is used in the aluminium window/door industry. The scanner allows them to measure newly developed profiles and accessories precisely and to compare it to original design specifications. They measure all new prototypes during development to improve them to perfection and all first deliveries of newly developed profiles and gear to check tolerances from the original design.
The CMM’s non-contact laser probe is a new technique to inspect the dimensions and geometric shapes of profiles and accessories. It measures accessories automatically and replaces older manual measuring with callipers and profile projectors. Scanning results are combined with CAD data to compare products with the theoretical design dimensions and tolerances.
An advanced sensor probe serves as a contact high precision measuring head to outline the contours of multiple samples in one movement and in 3D. The contours will be evaluated with the CAD data in order to approve or reject prototypes without having to flatten or remove inflections of aluminium samples.
The CMM’s accuracy enables Reynaers to comply with ISO-standards, ensuring lower tolerances and better alignment of parts at installation. The CMM will supplement Reynaers impressive arsenal of lab equipment that includes amongst others the aluminium hardness tester Brinell. Brinell measurements are obtained by forcing a bullet into test material. The hardness of the material is determined from the intrusion.
A profile projector measures dimensions and matching tolerance fields on profiles and gaskets. Test samples are enlarged tenfold by a lens and then manually measured. The Romidot measures dimensions and matching tolerances on profile prototypes and first deliveries. A 2D picture of the intersection of the profile is made with a scanning device after which the picture is automatically compared with the technical design drawing and tolerance fields.
The Aluroller SF
After 6 years of development, Reynaers and Aluro launch the state of the art Aluroller SF to thermally insulate and assemble aluminium profiles at their plant in Duffel - the biggest insulation entity for aluminium profile production in Europe.
This machine is far ahead of its time, incorporating the production principles of LEAN- , SMART and GREEN manufacturing in one entity. It is highly automated to deliver 10% to 20% faster running times, has zero defect tolerances, easy adaptability and faster setting times to insulate new designs and different frames without human intervention.
The Aluroller clamps profiles completely into position over their entire lengths during assembly, ensuring the profiles remain 100% stable. Older machines required a correction mechanism through which warped profiles would subsequently be corrected, leading to internal stress within the profiles. These stresses often later cause the profiles to warp again leading to maladjustment of corners and poor workmanship.
The Aluroller SF is now the only machine in the world to consistently deliver correct, stress-free insulated aluminium profiles and for the first time right with zero defects. It also allows for quick conversion from one to the next kind of profile with its own specifications and measurements.