Detachable Subdivision
"Rivne Professional College of
National University of Life
and Environmental Sciences of Ukraine"
Teachers and students had a great opportunity to get acquainted with the enterprise of the manufacturing sector, its production processes, principles of placement, organization and structure of production; with the content of the work of people of various specializations; with measures to preserve the environment. All the main technological processes of profile processing and the manufacture of double-glazed windows are automated at the production facilities of TM EPSILON.
In accordance with the technological map for window manufacturing, the following processes are carried out:
– cutting of PVC profile on a double-edge cutting machine of a well-known German company. Precise positioning of even a long profile is easily achieved using a linearly movable carriage and a clamping system. A characteristic feature of the machine is the quality of the cut, identical to grinding. The ability to simultaneously cut two pieces of profile increases the speed of window manufacturing. Control is carried out in dialog mode using a TFT display;
– the production of windows is carried out with an emphasis on the quality of the products produced. This applies even to those details that are hidden from the consumer, but play a key role in its functioning, reinforcement being one of them;
– creation of ventilation holes (drainage) in the profile;
– laying metal reinforcement in the profile;
– drilling a hole for the handle on automatic centering machines, which eliminates the risk of incorrectly installed fittings;
– welding of prepared profiles on joining presses. Two joints are processed simultaneously with automatic centering of surfaces, which eliminates distortions and torsions that negatively affect the quality and further production of windows;
– the production of windows with an aesthetic appearance is impossible without cleaning the surfacing. The production is equipped with a four-axis CNC machine for cleaning surfacing and grooves for the seal from the German company Sturtz. High-precision control of all processes is carried out via a computer built into the system. The choice of control scheme is left to the operator. Control can be carried out centrally using a specialized program;
– installation of locking mechanisms (hardware) is carried out at specialized hardware assembly stations. Screw misalignment, twisting, thread breakage, and inaccuracy in joining mechanisms are excluded.
Every owner of metal-plastic windows would like to have a structure that performs the functions of heat protection and energy saving. All the best qualities that meet such requirements are embodied in products using low-emission glass - the so-called thermal glass.
Low-emission glass is glass with an optical coating based on metal oxides (in particular, silver), which is obtained by magnetron sputtering. The process of manufacturing high-quality double-glazed windows from thermal glass requires the manufacturer to be highly qualified and have a true art of execution. Therefore, the appearance of such products in the manufacturer's assortment list is a decisive indicator of its professional capabilities and progressiveness.
EPSILON is one of the few companies in Ukraine that has a technological and technical base for processing thermal glass, as well as a proven technology for filling double-glazed windows with argon and krypton and its proper sealing, which prevents leakage of the gas filling. Manufacturing windows using energy-saving technologies is an important area of the company's activity. Back in 2008, the EPSILON brand introduced its customers to its proprietary innovative developments - energy-saving double-glazed windows EPSILON (with argon filling), which have unique heat transfer resistance, improved light transmission coefficient and natural color neutrality.
For the production of double-glazed windows, a high-performance automatic line from the Austrian company Lisec (Austria) has been used since 2012. Everything is automated, from loading and cutting of sheet glass of the Jumbo format 3210mm*6000mm of production. And the subsequent production of double-glazed windows using inert gases and a secondary sealing robot. The line is controlled by a complex program that requires minimal human participation in the process. This allows you to minimize operator errors and process workpieces with high accuracy.
The automatic glass cutting table allows you to process both regular and low-emission glass of jumbo size. This glass format makes cutting virtually waste-free, significantly reducing the amount of work. Window manufacturing becomes cheaper and this has a positive effect on the final price of the product. High cutting accuracy and computer-controlled cutter pressure eliminate the formation of chips on the ends of the glass, and its transportation on an air cushion eliminates the possibility of mechanical damage to the surface.
The automatic line for washing and assembling insulating glass units has a unique water filtration system, a four-stage washing unit with six cylindrical brushes and a drying zone. After washing, drying and quality control of the glass, the line assembles and presses the insulating glass unit with dry air or argon filling without human intervention, thereby eliminating contamination or damage to the glass after passing quality control.
The preparation of the aluminum frame is carried out on a machine for manufacturing distance frames in a non-jointing way, which is very important when filling the double-glazed window with argon, since the quality and durability of the gas filling directly depends on the manufacturer's qualifications. The application of primary sealing to such a frame occurs without breaks, and since it is the primary sealing that ensures the tightness of the double-glazed window, we can confidently guarantee a long service life of the double-glazed window.
The automatic molecular sieve (dehumidifier) frame filling machine supplies the absorbent from a sealed package under pressure, ensuring the presence of the required amount of absorbent in the spacer frame of the double-glazed window, and accordingly, the production of double-glazed windows that do not sweat throughout the entire service life.
2015 was the year of the launch of three lines for the production of profile systems by the extrusion method by the GREINER company (Austria).
Launch of production of window profile systems:
– Epsilon Basik (three-chamber system with a mounting depth of 58mm);
– Epsilon Optima (six-chamber system with a mounting depth of 70mm).
Window manufacturing is a complex automated technological process with increased risk. To manage this process, marking is applied at each stage of production in accordance with the order card. This technology eliminates the possibility of errors in the production cycle. Thus, a ready-made frame and glass unit with appropriate marking are delivered to a special assembly table.
The production has a mechanism for controlling factors affecting the production of windows at all sites by the technical control service (TC). Incoming control checks all components before using them in the production process. Then there is linear control at all sites and quality control at the end of the production line. Also, tests are systematically carried out for the strength of the weld and the tightness of the double-glazed window.
The finished product, after being inspected by the TC service, is packaged in film for transportation to the customer to avoid mechanical damage.
The technology of manufacturing non-standard products opens up freedom of choice for fans of individual architectural style. The enterprise manufactures not only standard windows, but also exclusive designs – arched, triangular, oval, trapezoidal, round, polygonal. Almost all non-standard windows can be made with opening sashes, while ensuring reliable hydro-, noise- and heat insulation. TM EPSILON also produces sliding and turn-sliding window and door systems, which is extremely convenient in a situation of limited space, as it saves the space required for opening general turn- or tilt-and-turn systems.
The original decoration of windows and doors can be bars, both overhead and inside the glass unit. Bars divide the surface of the window and are used to imitate traditional design forms. Such elements are widely used in the restoration of old houses. They give the facades of new houses a complete individuality.
In addition to the students of the construction department, the head of the construction department, Shalay Serhiy Vasilyovych, the head of the construction discipline cycle commission, Chorna Iryna Vasilyovna, and the teacher, Shaperchuk Stepan Vitaliyovych, took part in the educational tour. All practical experience will be used during classes with students.
Anatoly IVANCHENKO,
teacher of construction disciplines
