Corner press for aluminium and PVC windows and doors
A corner press is a key piece of machinery in the manufacture of windows and doors. The machine ensures that window and door profiles are precisely joined together to form a sturdy assembly.
For window and door manufacturers handling larger volumes, an automated corner press can help to make production faster, more consistent and more efficient. Automation plays a particularly important role when the machine forms part of a larger production line.
What is a corner press?
A corner press is a machine used to join profiles together at a corner. In the manufacture of windows and doors, individual profile sections are first cut to size and prepared. They are then brought together and precisely aligned before the corner joint is made.
The machine ensures that the profiles are positioned correctly during this process and compressed with the correct force.
An automatic corner press (4-head) takes over a great many manual steps:
simplifying handling between the pressing of 4 corners – 1 cycle for 4 corners instead of 4×1 cycle
positioning the profiles correctly
aligning the corner precisely
automatically adjusting the machine for each profile type
pressing the corner with the correct force
creating a strong corner joint
passing the pressed frame on to the next stage in production
How does a corner press work with aluminium windows and doors?
In aluminium windows and doors, the corners are joined using corner fittings that are slid into the profile chambers. The corner press brings the cut profiles together, aligns them and presses them firmly onto the corner fitting with the correct force.
Automatic configuration by profile and order
With an automated corner press, the machine retrieves its settings directly from the production data. The profile type, dimensions and pressing positions are set automatically for each order. This allows you to process different types of windows and doors one after the other, without having to manually reconfigure or adjust the machine.
This offers you a number of benefits:
No set-up time: the machine switches automatically between profiles and orders.
No set-up errors: if it isn’t set up manually, it can’t be set up incorrectly.
Consistent quality: every corner is pressed
with the same precision and force, regardless of who is operating the machine.
Significantly less handling
Why do window manufacturers opt for automated corner joints?
Joining the corners is a labour-intensive step in the production of windows and doors. Profiles are fed in, aligned, pressed, and the frame is then removed. If this is done manually on a conventional single-head press, each step requires time, manpower and concentration.
If you integrate the corner press into an automated production line, that stage links seamlessly to the sawing and machining that precede it and the finishing that follows. The result:
Optimal flow both before and after pressing
The profiles arrive at the press ready for processing and in the correct order. Whilst the press is operating, the next frames are being prepared. After pressing, the finished component is automatically conveyed to the next stage. No waiting times, no searching, no heavy frames that need to be moved manually.
More frames per day
The corner press takes over the repetitive work and operates at a constant pace. The stage involved in finishing the corner joints runs in step with the rhythm of the entire production line.
Fewer staff required
You can produce more with the same number of staff – or even fewer – and you are less reliant on experienced operators.
Consistent quality
The machine operates using fixed, digitally set and optimal parameters.
Switching flexibly between orders
A mix of different profile systems, window types and dimensions? The machine retrieves its settings from your production data and switches over automatically. You can also process small batches or single items without any loss of production.
Improved ergonomics in the workplace
Aluminium frames are large, heavy and awkward to move. On an automated production line, your staff no longer need to lift, turn or carry them across the workshop floor. Transport and positioning are carried out automatically, and work at the press takes place at a comfortable working height. This means less physical strain, a lower risk of back and shoulder problems, and a safer workplace. What’s more, an ergonomic workplace makes it easier to attract and retain new staff.
Modern production lines often need to be able to handle different profile types and window and door sizes. Automatic settings and digital production data can help to switch between orders quickly.
Where does a corner press fit into an automated production line?
A corner press rarely operates entirely on its own when a manufacturer opts for extensive automation. The machine can be integrated into a larger system in which different production stages communicate with one another.
An automated production line for aluminium windows and doors might, for example, consist of:
profile feeding and storage
cutting and machining centres
transport and buffering
corner jointing – corner press
cleaning or further finishing
fittings assembly
sorting
logistical dispatch
How do you choose the right corner press?
A corner press is a long-term investment. If you choose the wrong one, that single machine will become the bottleneck of your entire production process. These questions will help you make the right choice:
1. How many frames do you want to produce per day, both today and within five years?
For small volumes, a conventional single-head press is sufficient. Are you expanding, or do you want to produce more with fewer staff? In that case, an automatic angle press integrated into a production line will enable you to get much more out of each shift. Choose a machine that can cope with your growth plans, not just your current order book.
2. How often do you change your profile or window type?
Do you work with a wide range of variants, small batches or one-off items? In that case, automatic changeovers based on your production data aren’t a luxury, but a necessity. Every minute spent on manual set-up is a minute of lost production time.
3. Does the angle press fit into a continuous production line?
A corner press never works on its own. Look at how the profiles are fed in and prepared, and how the pressed frames are removed. A fast press without efficient feeding and removal is less productive.
4. Can the machine communicate with the rest of your production line?
The corner press must be able to exchange data with your software, your other machines and the conveyor system. Ask who sets up this connection, and who is responsible if it doesn’t work.
5. What control system, how many CNC axes and what software does it use?
A reliable CNC control system, such as FANUC, guarantees a long service life and the availability of spare parts. Software developed in-house by the machine manufacturer can be quickly adapted to your requirements.
6. How many CNC-controlled axes does the machine have?
The more servo axes there are, the more the machine adjusts itself. Any axis that is CNC-controlled no longer needs to be adjusted manually by the operator. Having many servo axes means:
Fully automatic changeover: cutting blades, stops and supports move automatically to the correct position for each profile. No manual set-up time between orders.
Greater precision: servo motors position to within a fraction of a millimetre, time after time.
Repeatable quality: every setting is digitally stored and executed exactly the same way, regardless of who is operating the machine.
Greater flexibility: new profile systems or non-standard dimensions can be added via the software.
Fewer errors: no more incorrectly set stops or forgotten adjustments.
7. How ergonomic is the work carried out on the machine?
Do your staff have to lift and rotate heavy frames, or is this done automatically? A suitable working height and automatic transport will save your team a great deal of physical strain.
8. Who will be on hand after delivery?
Ask about commissioning, training and after-sales service. And find out whether you’ll be in direct contact with the manufacturer, or whether you’ll need to go through an intermediary.
At Soenen Hendrik, you’ll find a single answer to all these questions
Corner press, feed and discharge systems, control systems and software: everything is developed in-house and tailored to work together seamlessly. You deal directly with the people who build your machine, from the initial consultation right through to years after commissioning.
From individual machines to complete production lines
A corner press can be a key component within an automated production environment. But automation goes beyond a single machine.
For window and door manufacturers, it may be worth taking a look at the entire production process. Where are manual operations still carried out today? Where are profiles or frames temporarily stored? Which machines cause waiting times? And what data can be sent directly from the production control system to the machines?
By viewing these processes as a single entity, machines for aluminium windows and doors can be better coordinated with one another.
A machine manufacturer that develops both individual machines and complete production lines can integrate various parts of the production process.
Looking to buy a corner press for aluminium?
Anyone looking for a corner press or an automated solution for the production of windows and doors would be well advised to first map out the entire production process. The material, the profile types, the production volume and the desired level of automation determine which technology is most suitable.
The best solution therefore depends not only on the machine itself, but also on the way in which that machine is integrated into the overall production process.
Frequently asked questions about corner presses
What does a corner press do?
A corner press is used to join profile sections precisely and create a corner joint. In the case of aluminium windows and doors, this is achieved through a mechanical pressing process.
Is a corner press suitable for aluminium?
Yes. Corner presses are used in the manufacture of aluminium windows and doors to join profile corners together with precision.
Is a corner press used for PVC windows?
With PVC, the joints are usually joined by welding. This is why PVC requires different machinery, such as welding machines and machines for cleaning weld seams.
Can a corner press be integrated into a production line?
Yes. A corner press can form part of a larger automated production line in which, amongst other things, sawing machines, CNC machines, conveyor systems, buffers and sorting systems are linked together.
What determines which corner press is suitable?
Factors such as the material, profile types, dimensions, production volume, number of variants and the desired level of automation determine which machine configuration is suitable.
