Company name reserved - (Austria)

Customized SM-500-ZA

Development of an automated welding and cutting machine for the production of roller blinds

The Challenge

In the Fall of 2015 one of Europe’s major manufacturers of sun protection systems contacted SMRE. The company was to set up a complete production line for roller blinds and was looking for a solution to automate the process and create a high quality product of variable dimensions in less than 2 minutes.

The finished product had to be strong (seams had to be very well welded) and particularly attractive – the aesthetic component of the product was as important as the strength. The edges of the fabric – in PVC coated fiber glass – has to be very cleanly cut, and the cut had to be seared. The lower pocket-with-keder was going to be visible in the finished product and had to be of superior quality. The tolerance of the diagonals on the finished product had to be less than 2 mm. The machine was to accommodate rolls of various weights and dimensions.

The Solution

Starting from the concept of our SM-500-ZA machine for the automatic production of custom sized retractable insect screens, our engineering team designed a machine that automatically carries out the following operations:

  • Pull the fabric off the roll.
  • I Cut the fabric to size with twin motorized rotary blades.
  • Apply a coextruded PVC profile to the blind top.
  • Simultaneously weld a pocket-with-keder to the bottom.
  • Cross cut with a specially designed combined rotary/ultrasonic tool.
  • Sear the edges of the fabric for perfectly clean cuts.
  • Rewind the fabric on the aluminum tube.

Drastically reduced cycle time.
Computerized order management.

The new machine produces a perfectly cut and welded roller blind, rewound and ready for insertion in the box, in less than 90 seconds – 30 seconds less than the original goal.

Our automation team developed a software interface between the machine’s manufacturing software and our customer’s order database system for total automation of order management.

Superior welds. Impeccable precision.

A series of cleverly designed tools make sure the welded seams are extremely flat and straight. The powerful motorized electric rotary blade cuts through the profile and pocket with speed and great precision while the ultrasonic blade creates beautifully seared cuts on the sides of the blind.

The machine is now operating in our customer’s plant in Austria. Our customer required his name not to be revealed.