z-transfer for sealing profiles with a metal or plastic carrier

A high availability of production systems requires standardized universal machinery with a proven track record.

High flexibility is paramount. Our quick-tool-change interface enables you to easily set up your system with the product-specific tools you need.

z-transfer production lines for secondary processing of sealing products allow for maximum output and parallel operations as well as the possibility of integrating various process steps.

z-transfer
The z-automation transfer concept for production lines is a standardized universal parallel system and can be individually combined with a variety of optional functions and automation modules: sawing, punching, cutting, milling, injection moulding, bending, robot integration, automated loading, automated unloading, suction, measuring, integrated tool storage. It is up to the customer to decide which function modules and which degree of automation are needed.

Products are transported from module to module on workpiece carriers equipped with easily exchangeable, product-specific holding fixtures. This means that the product stays clamped in place throughout the whole processing. During the machining processes at each work station also the workpiece carrier is exactly centered and clamped.

Left and right parts are usually transported on one workpiece carrier and processed at the same time at the work stations.

Length positioning for machining is carried out by highly precise NC axes. Measurements are entered into the parameter set of the product via the universal control system.

Typical cycle time
16 seconds for a product pair (left and right part).

Sawing
Two different solutions: On the one hand we offer universal double saws which can be set at different angles and are used at any of the system’s work station. On the other hand there are flexible sawing robot cells with automatic angle-setting which are ideal for the simultaneous production of a mix of products.

Notching and cutting
Pneumatic or hydraulic notching tools, set up on the system's universal work station via the quick-tool-change interface. The control unit checks the home and operating positions.

Injection moulding
z-automation has developed a unique injection moulding unit which has been optimized for the processing of TPE.
With the control unit integrated into the overall system control, there is no need for a dedicated operating unit or setting new parameters after changeover. Shot volume of up to 4 cm3 with a screw diameter of 14 mm and a piston diameter of 6 mm. Optional increased shot volume of up to 14 cm3 with a piston diameter of 24 mm. The complete system includes a quick mould change unit, a granule feeding and drying system, temperature control units for aggregate cooling and temperature control for the injection moulds.

Bending
Extruded parts often do not perfectly match the contours of the vehicle. z-automation has years of experience with automated bending processes.

Automated loading
Raw profiles are automatically taken from a buffer area and clamped onto the workpiece carrier. This makes the operator less dependent on the cycle of the system.

Automated unloading
Finished products are automatically released just before the workpiece carrier returns to the operator station. They are then automatically discharged and left and right parts are separately returned to the operator. This means there is no manual removal of products by the operator before new raw profiles are loaded onto the carrier. Depending on the type of profile, this can save up to 3 seconds of cycle time per product pair.

Integrated suction unit
The importance of correctly configured and implemented suction modules for sawing and milling operations as well as their seamless integration into the control system is often underestimated. z-automation supplies you with a turnkey solution.

Integrated tool store
Most systems supplied by z-automation are used for the production of more than one product. Our integrated tool store solves the problem of where to store the additional tool sets. We provide optional tool storage which is mounted on the side of the system and from which tools are safely moved into the machine with a rack feeder. This means that all tool sets are located “within the system” even if they are not in use. Discharging of tools for maintenance is also supported.

Maintenance and service
To guarantee a smooth operation for our customers, z-automation relies on proven systems, the use of commonly available parts, detailed operating and maintenance manuals as well as remote maintenance via online remote control.

Your benefits

• Process capability
• Tightest tolerances
• Products displaying maximum optical quality
• Maximum performance and minimum scrap rate
• Flexible universal systems which can be set up with product specific tool sets

How can we help you? Contact