Apart from classic frame manufacture by hand, automated processing with welding systems or bending machines is also possible. SWISSPACER supports insulating glass unit manufacturers with an extensive range of services.
SWISSPACER spacer bars can be processed into frames very easily by hand – push-fit corners ensure top quality.
Even for smaller production runs or projects, making the frames by hand remains the most widely found method. Manufacturers of insulating glass units can process SWISSPACER spacer bars very easily and without great effort on existing production lines. To ensure that the manufactured frames are always of top quality, a number of important points have to be considered.
First, the spacer bars should be stored in a dry and heated area and protected against dust before they are used. After removing them from the box, ensure that the spacer bar profiles do not come into contact with the ground when they are carried to the cutting bench. When cutting the spacer bars to the desired length, they must be securely positioned in the machine to achieve a clean cut. Blowing off the spacer bars with deionised air is also recommended – this prevents the build-up of any electrostatic charge. Once the spacer bars have been cut to length, they are assembled into frames. This involves inserting corner keys or longitudinal connectors into the spacer bar profiles at both ends up to the stop. Finally, the finished frame should be suspended on a frame gallows for the next processing steps.
Automated processing (welding)
Automated (ultrasonic) welding makes it possible to manufacture perfectly fitting SWISSPACER spacer bar frames in a highly efficient way and with the shortest cycle times.
Automated processing through (ultrasonic) welding
In the industrial production of insulating glass units, SWISSPACER spacer bars undergo automated processing into a finished frame as a general rule. In fact, (ultrasonic) welding enables especially economical and time-efficient processes. To this end, Rottler und Rüdiger und Partner GmbH (Langenzenn) offers various models of modern welding machines – for maximum processing quality and efficiency. With the high-speed and high-tech welding machine Rowelo, for example, SWISSPACER frames can be manufactured in a cycle time of less than 30 seconds. With very precise frame corners and a high-quality finish.
The production process is as follows: First, the spacer bar profiles are automatically retrieved from a magazine, conveyed to the cutting machine and mitred. Next, the cut spacer bar profiles are placed by hand into the welding machine and then automatically brought together, pre-positioned and welded using ultrasound. The frames made from SWISSPACER spacer bars are then sent for interim storage on special frame gallows.
Automated processing through hot bending
The automated hot bending procedure is a method for the extremely efficient manufacture of high-quality SWISSPACER spacer bar frames.
Automated processing through hot bending is perfect for manufacturing SWISSPACER spacer bar frames in a time-efficient and economical way. The latest bending systems produce aesthetic corners and achieve cycle times of approx. 60 seconds for hot-bent frames, depending on the size. As SWISSPACER spacer bars can only be bent while warm, the systems used for processing them must be equipped with a heating option.
Depending on the machine technology, the frame manufacturing process runs as follows: First, the spacer bar magazine is filled. The spacer bar is measured in the machine, then warmed by the heating element and bent straight away. Depending on the machine being used, the inner frame corners can be rounded or be given virtually sharp 90° corners. Finally, the profiles are (manually) assembled with a longitudinal connector. Hanging the finished spacer bar frame on a gallows is recommended for the rest of the processing steps.
The following manufacturing partners offer bending machines for SWISSPACER spacer bars:
- Lisec Austria GmbH (AT)
- Lombarda Macchine S.r.l. (IT)
- Forel Spa (IT)
- Rjukan (Norway)
- Beijing Boza Automation Machinery Co., Ltd (CN)
Manual processing for special shapes
For round or oval insulating glass units, SWISSPACER spacer bar frames can be hot bent very easily by hand.
Manual processing for special shapes
For the manufacture of windows with special shapes – for example, oval or round – SWISSPACER spacer bar frames can also be hot-bent by hand for the required insulating glass unit. Even complicated shapes and small radii are possible.
The processing can be done on a bolting bench from Rottler und Rüdiger und Partner GmbH (Langenzenn). To ensure greater dimensional stability during the heating procedure, the profiles should be filled with desiccant before the bending process (e.g. with gravity filler). Next, the SWISSPACER spacer bars are heated in an oven or with a hot air blower (industrial standard) at approx. 115 °C for 2 to 3 minutes. After heating, the desired radius can be formed over a three-roller system or a negative template. Semi- or fully automatic processing can also be implemented for bar systems – with the Quadrobot, for example. The vertical assembly machine from Rottler und Rüdiger und Partner is specially designed for fixing bar lattices in spacer bar frames. For the rest of the processing steps, the finished frame is hung on a special frame gallows.
Our animated explanatory videos on various processing topics
Offering our customers the best technical service is very important to us. We work constantly on improving our service and approach our customers proactively to offer them the best support. Our primary goal is to offer more information for a better understanding of our products and how to process them.
We have therefore created a series of videos on various processing topics. The videos provide easy to understand explanations, supported by interesting visualisations.