The topology of the fully automated production line for sectional doors.

© Sigmacontrol

"We got in touch with Weber Maschinenbau from Zwaag back in 2007 when we purchased our first profile processing line. We needed a special punching machine with which we could produce curved shapes for garage doors. After a short time, we invested again - in an extremely fast, 90-degree bending machine with which we could produce curved pieces with special connecting holes," says Jaap Kwant, founder and managing partner at ConDoor, recounting his first experiences with automated systems. When the decision for a new state-of-the-art production line was made in 2014, the company once again brought on board the special systems manufacturer Weber Maschinenbau and with it the experienced system integrator Sigmacontrol from Barendrecht (NL), which - as with the first line - was once again responsible for the complete automation based on components from the Austrian system manufacturer Sigmatek.

When it comes to drives, Weber Maschinenbau has opted for the compact SDD 300 and MDD 100 multi-axis systems from Sigmatek. The drives can operate servo, linear, high-torque and asynchronous motors.

© Sigmacontrol

Against this background, Sig-matek's multi-CPU strategy fitted perfectly into ConDoor's concept. This involves dividing the entire line into smaller, manageable functional units, each with a separate processor module. "This means that the units can be tested independently of each other and commissioned individually, which is a considerable simplification for a system of this complexity and saves a lot of time," explains Niels Joosten, responsible for programming this project at Weber.

The extremely slim control system saves valuable space in the control cabinet and can be expanded with a modular safety controller as required.

© Sigmacontrol

With the slimline S-Dias series, the space required for the control solution is extremely small - even the CPU modules measure just 12.5 mm in width. The units can be easily and completely modularly expanded with safety control units. Accordingly, all emergency stop circuits at ConDoor, including the numerous installed solenoid interlocks for the safe monitoring of the protected areas, are covered by the control concept.

From Weber Maschinenbau's point of view, the ConDoor requirement to optimize the use of materials was a key aspect of the project. The aim was to produce as many segments as possible from the available standard panel lengths with the least amount of waste. In order to achieve this, however, a solution first had to be found with which the panels could be optimized and cut to size across all orders. Kees Geelhoed explains the solution.

System optimization reduces waste

The 'fathers' of the new production line: ConDoor founder Jaap Kwant (left) and Kees Geelhoed, Managing Director of Weber Maschinenbau.

© Sigmacontrol

"We use a special software application that allows us to divide the production volume very evenly over an entire working week. The daily production is divided into batches, each comprising up to 20 gates. The product mix within a batch ultimately gives us the flexibility we need to optimize the use of the individual machines. After cutting, the panels are returned to the assembly line in batches. We have been working on this for a long time: Sigmatek's so-called de-nesting software continuously arranges and tracks the orders. All parts of an ordered door are brought together in a buffer zone and then transported onwards. For delivery, all parts must be stacked in such a way that the customer can always remove the components in the correct order on the construction site to install the door."

The production line is connected to the plant-wide ERP system via FTP. The ERP first creates a job list for each batch. This is forwarded to the machine control systems involved via Ethernet TCP/IP. In addition, the ERP provides an associated file for each panel, which contains information about its specific options. The HMIs from the ETV series, also from Sigmatek, with their 12.1-inch and 19-inch touchscreens, ensure that the order details of a batch can be clearly displayed for the operator alongside important and time-critical system information.

From ERP directly to production

The entire production process is structured and organized in such a way that the shift supervisor only has to confirm the start of production of the batches. However, he can change their sequence manually if necessary. Niels Joosten explains the solution in the software application: "Even before a single panel enters the production line for a new batch, the status messages of the individual controllers are queried using around 200 different telegrams. On this basis, the use of the system is planned for each individual batch."

The so-called 'Machine Manager' is used to set up the data transfer between the compact CPUs of the functional units. With the graphical software interface, the required data connections can be set up very easily using drag & drop. The Machine Manager also clearly displays all CPUs in the machine network and the Lasal applications for control, visualization and safety can be opened directly with a single mouse click.

Company founder Jaap Kwant attributes ConDoor's continued strong order situation and ongoing success to a large extent to the investment in the system described above and the perfectly designed automation system, which makes fast and efficient production possible in the first place.