CNC technology makes inroads

The Gewerbliche Akademie für Glas-, Fenster- und Fassadentechnik in Karlsruhe will have a highly flexible Weinig Vario MC 50 CNC machining centre from autumn this year: This will be equipped by the tool manufacturer Leitz with a tool system specially developed for the school for the production of wood and wood/aluminium windows, zero sills, changeable rebates as well as two different corner connections. Klaes’ software solution is used to make this possible. As in previous years, the aluminium shells required for the production of wood/aluminium windows come from Gutmann. Window construction consultant Raimund Drißner was also involved in the project. This will eliminate an investment backlog that has accumulated over many years in the woodworking machines in the Academy’s workshop. This was only possible, however, because the companies involved in the project came a long way towards helping the Academy financially.

The initiator, moderator and coordinator of the project is Werner Spohn, who is well known in the industry due to his many years of experience in the distribution of wood/aluminium systems. Using the network he has built up over many years and in numerous joint projects, he was able to win over the group of industry partners for the project.

“As a lecturer, I am in regular contact with the school and have inevitably also become aware of the technical conditions under which the training of window construction journeymen and master craftsmen takes place. The angle system used for this is over thirty years old and is still supplied with production data via a diskette,” reports Spohn.

Image gain as a side effect

In fact, the outdated equipment is problematic in several respects. Many companies in the sector complain about the lack of qualified skilled workers. In addition, the public image of the glazier and window maker trade is not as good as it should be and does not receive the recognition it deserves. The new facility is also linked to the opportunity to increase the reputation of the profession on the one hand and thus to arouse the interest of a larger number of young people in training as glaziers and window makers on the other. The GFF Academy aims to provide the specialist companies in the glass, window and façade industry with qualified, trained and further educated specialists and managers. “We do a good job in training journeymen and master craftsmen, which is also confirmed by the companies. But this also requires adequate machinery. With the Vario MC 50, we will soon have the missing link for our training,” says academy and school director Waldemar Dörr happily.

The concept in detail

After all project partners agreed to help the academy financially, the machine and production concept was designed in close coordination with the school over the last 18 months. This required a whole series of project meetings with all parties involved.

“We quickly became enthusiastic about the project. Because with the Weinig Vario MC 50, which is designed for the trade, we also offer the perfect solution for the academy,” reports David Eberhardt, product manager at the machine supplier Weinig.

The machine offers a wide range of applications in a compact space. The application spectrum of the CNC milling machine ranges from windows and doors to round arches, surface parts and many other applications. The Vario MC 50 combines the Weinig single collet technology with a continuous clamping bridge. As a result, users benefit from high flexibility and maximum precision during processing at the same time. The PowerGrip Motion 2D hemming clamp system is available in the standard version and enables new clamping positions. By adding a Z-axis, three-dimensional positioning of the tables can be realised. Direct part transfer ensures the highest machining accuracy and thus the best workpiece quality.

Expandable tool concept

“Training in the academy should be done with modern tools. Therefore, we considered it our obligation to develop not only the required tools, but also the window systems”, emphasises Engelbert Tiefenthaler, Sector and Product Management Windows and Doors at the tool supplier Leitz. For this purpose, a new modular tool concept was developed in a splitting process on the basis of several existing concepts. This enables the students to produce a range of wood and wood/aluminium systems as well as elements with a rebate change with the Vario MC 50. There is a choice between a counter dowel corner joint or Leitz’s Plug-Tec round tenon joint. “This also makes it possible to convey the advantages and disadvantages of the two connections,” Tiefenthaler explains. The tool concept also allows for later expansion to include doors – also with zero threshold – or lift-slide elements.

Under real conditions

“We are involved in the project as a leading software provider. The students will in all likelihood work with our software after they have completed their training”, explains Achim Binder, Technical Sales at Klaes. The teachers will be supported by Klaes employees in their lessons. The students, on the other hand, receive a software licence limited to the duration of their training. In the future, they will have the opportunity to work in a way that corresponds to the current conditions in the companies. From the creation of master data to production on the machine.

Experienced consultant

Raimund Drißner contributed his many years of experience, which has already been in demand for a large number of projects as a technical consultant at the tool manufacturer Oertli. “It was important for us to provide a machine and a tooling system that are state of the art,” says Drißner.

Open for further partners

It is not to remain with the current project partners. They are open to other companies that would like to contribute to the project with their capabilities. “Our concern was to make a start. Our commitment is to be understood as an initial spark that should encourage other companies to also get involved in the academy,” Spohn makes clear.

“Companies are dependent on good skilled workers. Therefore, something must be done about it. Therefore, together with the University of Cooperative Education in Melle, we have set up a bachelor’s degree course in “Window and Glass Facade Technology”, with which a bachelor’s degree in facade technology can be obtained in addition to the master glazier qualification,” adds Dörr.

The innovation push in the academy’s wood workshop is to be officially celebrated at the beginning of next year. We will report on the further progress of the project.

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