SM-520-ZA

AUTOMATIC WELDING STATION FOR RETRACTABLE INSECT SCREENS

STREAMLINE YOUR INSECT
SCREEN PRODUCTION

First introduced in 2005, machines of the 520-series caused a revolution in the insect screen industry by drastically reducing the production time needed to make a screen, the necessary man power, and the discards.

With its wide variety of tools, accessories and software solutions, this machine is, by far, the most complete manufacturing solution for quality 6 meter profiles and custom-sized retractable insect screens solutions available on the market today and will deliver the efficiency and quality that you are looking for.

With more than 150 units supplied to major manufacturers of insect screens in Europe and beyond, machines of the 520-series have proven their worth and reliability throughout the years and are a benchmark in the industry.

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PRODUCTS AND APPLICATIONS

SM-520-ZA allows operators in the insect screen industry to create retractable screens of any size with uncompromising quality and efficiency.

Main features

Machines of the SM-520-ZA series are truly revolutionary systems for the automated production of custom-sized and 6 m retractable insect screens. The first – and only – machines in the world that manufacture completely finished screens ready for installation in a continuous cycle.
A complete production cycle for a ready-to-fit 6 m retractable insect screen, perfectly cut and welded, rolled up and inserted in the box, with the hand grip attached, takes exactly 2 minutes and 48 seconds. A 3 m insect screen is ready in less than 2 minutes.
SM-520-ZA has a simple but very solid structure. Top of the bill electronic and pneumatic components and precision welding tools make this machine the best available on the market. The machine’s standard usable width is 2,8 m with a length of 6,0 meters. A smaller version – of the SM-500-ZA series with usable dimensions 2,8 x 3,0 m – is available for the exclusive production of custom sized screens. Extension modules of 2,0 m each can make your insect screen machine as long as required.
SM-520-ZA was developed to be operated by unskilled operators. With its easy-to-understand, simple-to-use touch screen anybody can work with this the machine. To further reduce human input – and risk of human error – the machine can be connected with a bar code reader. By simply reading the code the machine will set the parameters for the next production job itself.
SM-520-ZA works in full automatic cycles. Once the machine is set, it will weld, cut and rewind the retractable insect screen until the full cycle is done and the product is ready. All in an extremely limited cycle time.
Machines of the 520-series carry out multiple steps in the production process simultaneously and fully automatically, resulting in significant saving of man power. To work with the machine, only one operator is needed.
Operating costs are extremely limited. Maintenance costs are negligible. The machine is so sturdy, its concept and structure are so simple, that it will go on forever.

CLEVERLY DESIGNED TOOLS AND ACCESSORIES

SMRE offers a wide selection of industrial tools: they can be installed individually or simultaneously, in a variety of combinations, providing an enormous versatility of applications.

Welding group for (coextruded) keder

Welding group for (coextruded) keder

Pocket welding group w/ automatic insertion of reinforcing tube

Pocket welding group w/ automatic insertion of reinforcing tube

Welding unit for lateral reinforcing strip

Welding unit for lateral reinforcing strip

Motorized rotary knife

Motorized rotary knife

Automatic rewinding unit of the cut and welded insect mesh on the aluminum bar

Automatic rewinding unit of the cut and welded insect mesh on the aluminum bar

Pneumatic mechanism for the automatic positioning of a new aluminum bar

Pneumatic mechanism for the automatic positioning of a new aluminum bar

System for the semi-automatic insertion of the rolled up insect screen in the box and the automatic attachment of the lower hand grip

System for the semi-automatic insertion of the rolled up insect screen in the box and the automatic attachment of the lower hand grip
Welding group for (coextruded) keder

Welding group for (coextruded) keder

Applies a coextruded profile to the upper side of the mesh while the grip-and-pull system pulls the insect screen from the roll. A customized guide and roller mechanism makes sure the profile is applied with great precision and that the seam is strong and aesthetically impeccable.
Pocket welding group w/ automatic insertion of reinforcing tube

Pocket welding group w/ automatic insertion of reinforcing tube

Automatically welds a folded PVC strip to the lower, or to the upper side of the screen. While the grip-and pull system pulls the screen from the roll and spreads it on the table top, a guide and roller will fold the strip and automatically insert a tube, thus creating the pocket with which the mesh is attached to the lower hand grip of the insect screen. This operation is done fast, precise, and without any intervention of the operator whatsoever. Guides and rollers are custom built, according to your production requirements.
Welding unit for lateral reinforcing strip

Welding unit for lateral reinforcing strip

Automatically applies a reinforcing strip to the left and right sides of the insect screens. The motorized rotary knife with pentagonal blade runs across the width of the table and cuts the strip straight through the middle, thus creating the left side reinforcing strip of the finished piece, and simultaneously the right side strip of the subsequent piece.
Motorized rotary knife

Motorized rotary knife

Cuts the insect mesh off of the roll. When the grip-and-pull system has pulled the fabric to the programmed length, a pressing bar secures the fabric in place. The motorized rotary knife now makes a fast, very precise cross cut along the width of the table. With its razor sharp pentagonal blade and the high speed with which it rotates, the motorized rotary knife makes a fast, high precision cut.
Automatic rewinding unit of the cut and welded insect mesh on the aluminum bar

Automatic rewinding unit of the cut and welded insect mesh on the aluminum bar

Automatically rewinds the cut-and-welded insect screen on the aluminum bar. An electronic sensor in the table surface recognizes the end of the fabric and automatically stop the rotating motion a fraction of a second later. With this accessory an otherwise very time consuming and imprecise step in the production cycle is carried out fast and with great precision.
Pneumatic mechanism for the automatic positioning of a new aluminum bar

Pneumatic mechanism for the automatic positioning of a new aluminum bar

The structure can hold up to 20 aluminum bars. At the end of every cycle this device will automatically put a new aluminum bar in position, ready for the upcoming cycle. A series of pneumatic cylinders will make sure that every new aluminum bar is placed smoothly and silently.
System for the semi-automatic insertion of the rolled up insect screen in the box and the automatic attachment of the lower hand grip

System for the semi-automatic insertion of the rolled up insect screen in the box and the automatic attachment of the lower hand grip

An (optional) station inserts the rolled up insect screen in the box and automatically attaches the lower hand grip to the screen. This station carries out an otherwise difficult to manage and time consuming operation and completes the production cycle.

Technical specifications

Available usable dimensions
Width x length (m) 2,8 x 3,0
Width x length (m) 2,8 x 6,0
Extension modules (m) 2,8 x 2,0 m
Power (kW) 5
Voltage (V) 380 (3 phases + N + E)
Circuit breaker (mA) 300
Air (Quality Class 1.4.2.; ISO 8573) (bar) 6
Air consumption (nl/min) 300
Max. bridge speed (m/min) 30
Certification 2006/42/EC; 2014/30/EU; EN ISO 12100
SM-500-ZA
Footprint Machine 2,8 x 3,0 m
X (mm) 6177
Y (mm) 3940
H (mm) 920
H MAX (mm) 1556
Weight (KG) 1550
SM-520-ZA
Footprint Machine 2,8 x 6,0 m
X (mm) 9080
Y (mm) 4106
H (mm) 920
H MAX (mm) 1768
Weight (KG) 1664

Software solutions

Specifically developed software assists the operator in quickly setting up the machine for the production of screens of any chosen size. Numerous different end products can be programmed on the touch screen interface, with up to 99 repetitions each. The optional bar code reading program enables to set the working parameters with a simple “beep” of the reading gun, further reducing the possibility of human error.