Extruded Aluminium Assembler

Challenge

Based in NZ, Altus (previously NALCO and Fletcher Aluminium) is a leading manufacturer and exporters of aluminium extrusions and extrusion building systems.

They operated an existing thermal break machine to feed window and door extrusions into their resin application process. When changing from one extrusion size to the next, the changeover process had been manual and requiring very precise and time-consuming positioning. 

This manual fine tuning between every changeover was also resulting in huge product wastage and labour cost.

Solution

RML developed a solution whereby the manual vertical and horizontal adjustment controls were replaced by nine servo-controlled actuators. The accuracy of the servo positioning allowed very precise and repeatable setup of the line and a 97% reduction of product wastage. 

The assembly controls the size change of nine different points within the machine. 

Needing to be highly accurate, fast, robust and safe RML designed and manufactured a number of assemblies that were fitted to an existing AZON thermal break saw and chemical applicator. 

Using a recipe system stored within the controller the operator can easily select the product to be run, instigate the change and the servo motor control will position the mechanisms for that product. 

The improvement in changeover speed and accuracy has allowed Altus to process in less than a single shift, what used to take up to two shifts.