Unlocking the Possibilities: Motion Control and Electric Cylinders Transform Window and Door Production
- Paxton Shantz
- Sep 5
- 4 min read
Updated: Sep 9
PC-based control delivers new potential in window and door production
With a unique machine design, Belgian machine builders CNC Solutions and Calvet are automating previously manual processes in aluminum window and door production. High-performance drive technology, motion control, and the energy-efficient AA3000 electric cylinders from Beckhoff proved crucial in providing the machine with the necessary finesse for pressing window frames.
Zellik, Belgium-based machine builder Calvet N.V. aimed to extensively automate processes in their window and door production with a new machine concept. “Together with CNC Solutions, a machine builder specializing in customized systems like Calvet, and the automation specialists from Beckhoff, we were able to bring this sophisticated concept to life,” explains Stefan Nees, managing director of Calvet. “We were delighted to contribute our expertise in CNC and robot applications,” adds Lander Debruyne, managing director of CNC Solutions BV in Menen, Belgium.
Quality and productivity boost in window manufacturing
Until now, joining aluminum window profiles has involved corner presses. Before using the press, workers still needed to do several tasks by hand, requiring production teams to be extremely careful to ensure the final quality of the window or door frame. “We combined and automated the manual steps of assembly, gluing, pressing, checking, and polishing, all at a central workstation,” notes Nees.
Now, the operator places the window frame profiles on a mover. Sensors then ensure that the correct parts have been inserted and fit together properly. Once confirmed, the profiles are positioned, clamped over brackets, and pressed together with the appropriate force. “This automated process allows us to raise the bar in terms of quality and boost the efficiency of our window production,” says Nees.
Three electric cylinders make one gripper
Along with quality and productivity, flexibility was another top priority when designing the machine. Profile types, pressing positions, and bonding techniques all needed to be considered. To address this variety of needs, two 6-axis robots operate at the center of the installation. Depending on the size of the window being produced, anywhere from 300 to 4,500 mm, the robots move into place and automatically pick up the corresponding tool for each production step.
“What really sets our process apart is the special gripper for pressing the corners together,” enthuses Debruyne. Three AA3000 electric cylinders with spindle drives form the basis of the gripper. “By evaluating the currents and torques of these drives, we were able to give the machine a sense of the pressing force and control it dynamically,” clarifies Nees.
It is no surprise that CNC Solutions chose PC-based control and other components from Beckhoff for the machine. Lander Debruyne explains, “We switched to the Beckhoff platform and CX2043 Embedded PCs as standard controls around two years ago because we were constantly having availability problems with our supplier at the time.” CNC Solutions also uses Stäubli robots, which can easily be connected and controlled via EtherCAT and uniVAL drive technology. “Changing the control technology is not something that can be done overnight,” explains Debruyne, “but with application engineer Maarten Knevels by our side, we always had a true expert on hand.”
Customers now use as many as seven machines with PC-based control. “Our application engineers provide support during the transition period to ensure a seamless launch and even help existing customers implement new technology,” adds Cédric Sabbe, account manager at Beckhoff Belgium.
In addition to the robots, 15 CNC axes (AM8000 servomotors and AA3000 electric cylinders) are controlled using TwinCAT 3 and the AX8000 multi-axis servo system. Calvet and CNC Solutions also use EtherCAT Terminals and EtherCAT Box modules with an IP67 protection rating to read the signals and control the actuators, which are mounted directly on the movers. Cédric Sabbe notes, “The compact drive system coupled with OCT technology have facilitated a space-saving and swift installation.”
Flexible combination of robots, CNC, and motion control
“The major challenge of this project was to ensure that every last process was perfectly coordinated,” says Nees. This is where TwinCAT 3 NC PTP, NC I, and CNC software came into play, managing the complex coordination of all axes. The operator receives setup instructions through the CP2918 Control Panel and then uses it to track machine operations. The order data is loaded from the central order management system using a barcode on the window profiles. Calvet achieves the necessary connectivity with the bar code scanner and IT systems via TwinCAT 3 Serial Communication (TF6340) and TwinCAT 3 Database Server (TF6420). “To keep operation as simple as possible, there are just two buttons for the machine operator to navigate to the next or previous step,” explains Nees. It couldn’t be simpler.
The first system has been set up at a window manufacturer in Brussels, where the machine is being put through its paces in the field. “This practical feedback will help us to develop the prototype even further into a high-performance standard machine for series production,” says Nees.
By combining advanced motion control, flexible robotics, and reliable PC-based automation, CNC Solutions and Calvet have transformed window and door production. Careful, time-consuming manual labor can now be done faster, smarter, and safer with the help of innovative machinery that still maintains the high-quality work they are known for.
Ready to open new possibilities in window and door production with advanced motion control and high-performance electric cylinders? Contact your local Beckhoff sales engineer today.
Paxton Shantz is the Digital Manufacturing Industry Manager at Beckhoff Automation