versuchsdurchfuehrung

Industry solutions

We will show you here which solutions we have developed for different sectors with concrete examples of implementation.

Mobility

Mobility

  • Steel profiles for truck chassis

    Stahlprofile für LKW-Fahrgestelle

    Task

    How can eleven different profile cross sections for truck steel profiles be produced quickly and economically?

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    Challenge

    1. Shortest set-up times for economical small batch production
    2. Pre-series from completion of the tools
    3. Profile geometry with long legs

    Our solution

    • The line was conceptually designed and optimized for fast setup times. As a result, 11 different profile cross sections are possible on one line.
    • Immediately after the tools were made, Profilmetall produced the profiles in small pilot series ex works in Hirrlingen, while the customer’s own roll forming plant was still under construction. this meant that truck profiles could be delivered to customers even before the plant was completed.
    • High-strength steel with a strength greater than 900 MPa was used on the roll forming line. This minimizes wear on the machine and ensures consistently high profile quality with minimum tolerances.

    Advantages

    • Time savings with time to market
    • Low investment costs
    • Energy-efficient and wear-minimized manufacturing process

    „PROFILMETALL convinced us with an excellent concept. The delivered machine has been working trouble-free for years and is a considerable relief for our production process.“

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  • Aeronautics frame profile

    Spantenprofil Flugzeugbau

    Task

    Production of a profiling line for frame profiles with different radii of curvature, both in titanium and high-strength aluminum.

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    Challenge

    1. Titanium processing
    2. Processing of high-strength aluminum in a deep-frozen state
    3. High production speeds (titanium 10 m/min, aluminum 35 m/min)

    Our solution

    • The profiling system we have developed influences the profile cross-section in a very targeted manner by means of partial rolling of specific profile areas.
    • Despite different materials with very different material properties, the system enables the desired rounding variants.
    • Several separate operations could be saved by integrating different processes in one plant.

    Advantages

    • Fast product manufacturing
    • Production of all required variants
    • Savings of several separate operations
    • High availability of the plant

    „We have put off investing in this plant for far too long. The result and the productivity gained is impressive.“

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Constructions

Constructions

  • Reinforcement profiles roller shutter boxes

    verstaerkungsprofile-rolladenkaesten

    Task

    Manufacture of a compact and mobile machine that produces galvanized steel reinforcing profiles to order directly on the construction site, starting from a quantity of 1, in the required lengths.

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    rolladenkasten

    Challenge

    1. Integrate a 2 mm thick strip of galvanized steel into a compact tool to create a mobile machine
    2. Protect resistant to dust and dirt, so that the machine also provides the best quality at the place of use (construction site)

    Our solution

    • Although 2 mm thick galvanized steel is to be processed, we were able to design a compact machine.
    • The machine saves the customer time-consuming bending processes on the construction site.
    • The required reinforcement profile is available directly on site (construction site).
    • Any desired quantity can be produced from as little as 1 piece.
    • The machine is optimally protected against external influences thanks to a protective housing.

    Advantages

    • Customer sorting through demand-oriented production on site
    • Eliminates complex logistics
    • Speed and cost savings

    „With the new mobile profiling line, we are quickly on site and produce profiles as needed directly at the construction site. Super efficient and environmentally friendly!“

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  • Beading profiling shutters

    sickenprofil-fensterlaeden

    Task

    A profiling line for the production of aluminum shutters as part of a complete line.

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    fensterlaeden

    Challenge

    1. Despite the width of the profile, the flatness of the panel should be maintained
    2. Integration of roll forming into a customer’s own production process
    3. Previously manufactured by a press brake, production times are to be significantly reduced

    Our solution

    • The basic prerequisite for the good solution was good coordination with the customer’s project team.
    • We developed a machine with two pairs of rollers, one of which is almost 1.5 m wide and has a diameter of 300 mm.
    • The changeover from a cant press bench to roll forming technology speeds up the production process immensely.
    • By integrating the forming process into the production of complete shutters, several operations were saved.
    • The process-reliable flatness made the integration of bead production into the overall process possible in the first place.

    Advantages

    • 10 x shorter production times
    • High quality and process reliable flatness
    • Saving of several operations
    • Perfect integration of bead production into the overall process

    „The tool design for the flatness requirements of the aluminum profiles was an immediate fit.“

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Renewable energy

Renewable energy

  • Heat baffle solar collector

    waermeleitblech-solarkollektor

    Task

    Profiling line for the production of heat-conducting sheets for a solar thermal system that uses sunlight to heat a fluid passing through it.

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    solarkollektor

    Challenge

    1. Copper with Sunselect coating
    2. The extremely sensitive surface of the base material must not be damaged
    3. High precision of the groove necessary to ensure optimum heat transfer

    Our solution

    • We designed the tool in such a way that the strip is gently formed and the surface purity of the strip is not damaged. Thus, the absorption properties of the material were completely preserved.
    • Despite the gentle forming, we have achieved high precision of the groove, which leads to improved heat transfer. The previous calculations of heat transfer to the fluid were even exceeded.
    • The new plant also enables faster and more economical production.

    Advantages

    • High precision of the groove
    • Improved product properties
    • Higher efficiency
    • More economical production

    „Due to the highest precision in the groove, the result of heat transfer to the fluid – and thus the energy carrier – has improved significantly. Profilmetall has thus clearly exceeded our expectations.“

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Air conditioning

Air conditioning

  • Sun protection venetian blinds

    sonnenschutz-raffstores

    Task

    Entwicklung einer Profilieranlage zur Herstellung eines Aluminium-Kunststoff-Dämmprofils für Sonnenschutz-Raffstores.

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    sonnenschutz

    Challenge

    1. The different properties of different materials are to be used in a composite profile for darkening and noise reduction
    2. The base material has different properties; for example, yellow is painted three times to make it cover, this affects the thickness and hardness of the profile

    Our solution

    • Profilmetall Engineering was involved in the development of the new machine right from the product development stage.
    • The different properties of the base material were taken into account in the design and tool layout. Our tool is stable when using the different colors and thus the different material properties.
    • The rubber band (“welt”) is rolled inline directly during production.

    Advantages

    • Inexpensive, compact solution with low cost
    • Customer benefits from Profilmetall Engineering’s know-how
    • Development support
    • Feasibility studies in collaboration with customers and designers

    „The processing competence of the profiled metalworkers for various materials in a forming process is impressive and very purposeful for the functionality of external venetian blinds that we require.“

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  • Stainless steel composite profile glass spacer

    edelstahlverbundprofil-glasabstandhalter

    Task

    Manufacture of a machine for joining simultaneously formed stainless steel profiles at high machine speeds.

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    glasabstandhalter

    Challenge

    1. Simultaneous forming and bonding of two materials with different wall thicknesses
    2. Profiling and gluing in a plastic profile
    3. Profiling and co-extrusion with plastics
    4. Process strip thicknesses from 0.08 mm

    Out Solutions

    • Right from the development stage, we supported the customer in product realization and carried out feasibility studies.
    • The production line runs extremely fast at 70 m/min and welds inline.
    • Materials of different thicknesses with optimized properties for the particular application (thermal conduction, subsequent forming, insulation, etc.) can be joined together.
    • A flying cut-off with a special multi-knife cutting tool guarantees that the geometry of the profile is not deformed during cutting.
    • Our comprehensive service package enables fast and short response times and thus quick spare parts and tool supply.

    Advantages

    • Speed and high quality
    • Product variance
    • Joining materials of different thicknesses

    „Initially, we planned to integrate the solid-state laser ourselves. This presented us with immense problems. Thanks to the know-how and dedication of Profilmetall Engineering, we were able to obtain a functional profiling line within the planned timeframe, whose productivity far exceeded our expectations.“

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Electrical installation

Electrical installation

  • Beam profiles LED lights

    traegerprofile-led-leuchten

    Task

    Production of a profiling line for a carrier profile for the manufacture of LED luminaires

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    led-leuchten

    Challenge

    1. Forming of pre-painted steel without any surface marks
    2. Tight tolerances with complex profile geometry and hole pattern
    3. Numerous length variants
    4. Ensure high availability after delivery of the roll forming line

    Our solution

    • The profiling machine operates at high speeds, yet maintains the tightest tolerances and produces a stable profile.
    • Due to the flying separation cut, which is already prepared during the pre-punching process, the overall process does not have to be stopped.
    • The system is completely integrated into the assembly line – from coil to packaging ready for shipment.
    • A comprehensive service package and forward-looking spare parts planning ensure permanently high availability of the plant.

    Advantages

    • Speed and high quality
    • Rapid amortization of investment costs
    • High plant availability

    „Profilmetall Engineering combines the know-how for profiling systems and for series production. Therefore, we have entrusted our in-house profiling processes to this competent team.“

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