Automated systems for the manufacture of Venetian blinds with Z-shaped slats: the full range
External Venetian blinds are a highly promising sector of the market that is continually evolving: the manufacture of a ready-to-install Venetian blind, however, normally entails a considerable amount of labour especially when it comes to assembling the slats and applying the hooks and end or guiding pins.
With a view to satisfying customer requests, Dallan® has developed a complete range of automated systems for making Venetian blinds, from the simple ones with flat or rolled-edge C or F slats through to the blind with S or Z-shaped slats, which involves many subsequent steps. This article deals with the three most popular systems for making a Venetian blind with S and Z-shaped slats.
This Venetian blind firstly requires the following processes:
- Production of the slat with relative machining
- Application of the end – guiding pins
- Application of the side hooks
- Application of the loop tape to the hook
The first type of processing systems, suited to limited quantities, is the integrated start-stop system (photo). In this machine the profile moves forwards through the roll former and is accompanied throughout the various steps: roll forming, perforation according to programmable patterns, application of the side hooks and application of the end pins. At the end, all the slats of the Venetian blind curtain are stacked on top of each other and the operator can apply the loop tape – the only work that requires the human hand. This system can produce approximately 20 to 40m 2/h of curtains.
The second type of processing systems is the in-line system integrated with flying shears and intermediate buffer storage units. This system is suited to high quantities and for those companies wanting maximum automation. The roll former is fitted with flying shears so that forming moves continuously. In this case when the profile has been made by the rollformer, it is then taken by a conveyor belt, which also acts as storage unit, to the next station where the end pins are inserted. Lastly, the profile goes to a third machine, which simultaneously applies the side hooks and closes them onto the loop tape. A palletising robot then takes the ready formed bundle to a transverse collecting belt. The processes are decoupled and so this system allows a high output rate to be achieved by eliminating bottlenecks.
Finally the third system is defined as decoupled with independent machines (DAMI). The roll former, the end-pin application system and the machine that applies the hooks and the loop tape are fully independent in this case, although they are all located in the same production area. They perform the following tasks:
- the roll former produces the bundles of slats at maximum speed;
- the pin application machine works on ready formed packs: it takes the slats, applies the pins (by ultrasonic welding or clinching) and then stacks them again;
- the hook and loop tape application machine works on a ready formed bundle complete with end pins: it takes the slats, applies the hooks and the loop so that the operator is presented with the pack complete with pins, hooks and tape already inserted.
The advantage of this third system is its great flexibility and throughput. It is also extremely flexible in terms of layout for any company, since the three machines are independent; this also ensures production continuity even in the event of downtime for any one machine.
For the small, medium and large size business: Dallan has the solution for you to achieve your top results.