The Challenge
One of Europe’s largest manufacturers of high-end pergola systems asked us to develop a customized machine to apply extruded omega profiles on PVC-coated textiles and significantly increase their manufacturing volumes. As they specialize in pergola systems of large and extra-large dimensions supplied worldwide, they were looking for a solution to automate their processes and apply multiple profiles simultaneously, instead of welding one profile at a time.
Since the pergola systems are opened and closed numerous times, the welds created by our machine had to be extremely strong. Yet, they also had to be aesthetically pleasing to be marketed to the end customer.
The Solution
Based on our SM-321-HA machine for the continuous production of truck curtains, we adapted the welding heads so that instead of applying the classical horizontal and vertical truck curtain straps, they could weld the omega profiles.
To facilitate the unloading of empty bobbins of the omega profile and loading of a new bobbin, we installed a system that pneumatically lowers the bobbins so that they can be easily reached by the operator. As the machine is operated during at least 2 shifts per day, 6 days a week, we had to made sure the structure was both simple sturdy, with components of the highest quality.
Drastic increase in production output. High-quality products.
The SM-321-HA was the perfect machine for this job. Instead of welding one meter of omega profiles at a time with the traditional HF technology, our machine applies up to eight profiles simultaneously, at a speed of six meters per minute, thus increasing our customer’s production output more than 20 times.
The motorized unwinder installed underneath the machine structure features digital control of the fabric edge and automatic correction jumbo roll position. A digitally controlled dancer continuously checks and corrects the fabric’s tension to ensure welds of the highest quality and greatest precision for any sized pergola.
The machine has been producing quality pergolas since 2013.
