SOLUTION

Transfer line for cutting, stamping, and assembly of plugs in supporting square tubes – transfare line

In the furniture manufacturing industry, where competitiveness and flexibility are key, speed and precision in component processing are essential. Aluminium Kety Emmi Ltd., a manufacturer of furniture components for global brands, decided to enhance its production process for supporting square tubes with integrated plugs for a specific product. These tubes are designed as components for furniture systems, requiring high quality and precision. To improve productivity, reduce costs, and facilitate faster adaptation to different product dimensions and types, they sought advanced equipment capable of meeting these demands. The new line by BOS GRUBAR offers automated collection of cut square tubes in various lengths, orientation based on the weld, punching of blind and through holes for assembly at specific locations, as well as precise plug assembly and blocking via pressing. The introduction of a faster, more flexible, and optimized line enables Aluminium Kety Emmi Ltd. to stay competitive and meet the high standards of the furniture industry.

01 Problem

The previous manufacturing processes were designed as separate operations, which required multiple stages, manual labor, and took up a significant portion of the production area. Operations such as tube collection and loading, correct tube orientation due to welds, hole punching, plug insertion, and pressing were carried out on separate machines, with specific setups and manual handling for each operation. As a result, the process was slower, required more operators, and occupied more space, increasing costs and limiting flexibility.

02 Solution

BOS GRUBAR introduced a solution with a compact transfer line, integrating all key production operations into a single process, occupying less space and reducing operational costs. The transfer line features fast tube transfers between operations and rotation during transport, ensuring high-speed production without intermediate tube rotations, thus reducing cycle time. Simultaneous production of two tubes per cycle significantly increases production speed and reduces process time. The flexible receiving buffer allows collection of various tube lengths, while the optical system ensures correct weld orientation. The punching operations are performed with a press using quick-change tooling, enabling rapid adjustments, while vibration systems ensure precise and quick plug assembly with position control. The retractable exit unit allows easy transfer of finished products. All units are equipped with quick settings, allowing for changeovers between product types in under 10 minutes. The measuring rails ensure the correct product type is selected. The computer interface facilitates parameter control, batch tracking, and simplifies maintenance by allowing temporary disabling of specific operations.

Technical details of the solution:

Compact design with optimized space usage: The transfer line integrates all operations in a smaller footprint, reducing operational costs and improving space efficiency.
Fast transfer cycles and product rotation: The transfer line allows tube transfers with rotation, ensuring correct weld orientation and continuous production.
Flexible receiving buffer and optical weld detection: The receiving buffer accommodates various tube lengths, and the optical system ensures precise weld positioning.
Quick-change punching press: The press enables fast changeovers for different punching operations, enhancing accuracy and enabling quick tool swaps. It is controlled via a computer interface for type selection.
Computer control and ease of maintenance: The computer interface enables parameter monitoring and batch tracking, with units designed for easy maintenance or adjustment by temporarily disabling specific operations. All position changes are automatically controlled.

03 Results

With the implementation of the new transfer line for cutting, stamping, and assembly of plugs in supporting square tubes, Aluminium Kety Emmi Ltd. achieved the following results:

04 Conclusion

By implementing the new compact transfer line, Aluminium Kety Emmi Ltd. significantly improved production capacity and product quality while reducing manufacturing costs. The new technology provides greater flexibility in processing different product types, with changeovers completed in under 10 minutes. The integrated system, with computer control and operation, enables easy tracking of product quality and quantity while facilitating maintenance. The BOS GRUBAR transfer line allows Aluminium Kety Emmi Ltd. to efficiently meet the demands of the global furniture component market, strengthening its competitive advantage in the industry.