WEINIG Technology Initiative: Maximum efficiency in solid wood processing

New Powermat offers big savings potential
The new generation of moulders gives customers a choice of different models. All have the innovative Comfort Set operating concept. High-lights include the graphic support and operator guidance during setup, fast and precise spindle positioning via CNC-controlled axes and dimension changes while the machine is running. A window package is also available as an option. The Powermat models are recommended for processing highly complex profiles and also allow the creation of struc-tured surfaces.

Large dimensions in joinery quality
Working widths of 60 to 450 mm are the domain of the new Hydromat 45 planing machines. The high spindle speed and jointing system guarantee first-class surface quality. The large 300 mm axial adjustment of the horizontal spindles ensures long service life and even wear and tear on the tool cutting edges. Floating vertical spindles enable low chip re-moval and ensure high resource efficiency.

High process reliability with System Plus
The new System Plus links all processes upstream of production using a unique piece of software. Its capabilities range from the creation and management of tool drawings, profile drawings and production data to definition of the production process. There are also interfaces with the sharpening unit and controls. A CAD program is also integrated. System Plus significantly reduces the number of process stages from the product idea to the finished profile.

Rondamat 1000 fully automated CNC grinder
The new Rondamat 1000 is designed for fully-automated grinding of profiling cutterheads and straight planing heads up to a tool width of 360 mm. The profile is ground from a full blank rendering the production of templates unnecessary. Following setup, the machine works unmanned. An automatic tool changer with three magazine spaces increases profitability.

New processing units and tool clamping systems for the Conturex CNC window center
For as long as there have been wooden windows, the corners and connections of the horizontal and vertical transoms, mullions and glazing bars have been the most sensitive areas. The quality of these connections stands and falls on the gluing and the precision of the transversal and longitudinal processing. Besides the conventional methods, such as mortisetenon and dowel connections, the new, highly robust round tenon corner joints are increasingly establishing themselves in the windows and doors market. The initial results show a material improvement in terms of the bending and breaking strength of these connections. Manufacturing these corner joints is almost exclusively restricted to CNC centers. The concept of the Weinig Conturex with its open and flexible configuration is precisely tailored to round tenon production. Using new processing units and tool clamping systems, the Conturex achieves optimal precision and productivity. Even producing a mix of different connections is not a problem.
 
New tool cleaning station maintains high processing quality
The condition of tools has a significant influence on service life and wood surfaces. The effect of the different wood types, particularly softwood, on tool blades is often completely underestimated. During milling, layers of resin and glue are built up that become stuck in the chip area and on the tool body. These buildups and deposits in the chip area normally have serious consequences for service life and particularly for surface quality and even result in increased power consumption. Tools on CNC systems work with significantly higher speeds than on conventional machines and, therefore, react more sensitively to the aforementioned influences. The result is increased imbalance and uneven chip removal. Regular cleaning of valuable tools is, therefore, highly recommended for reasons of cost-effectiveness. The level of care is adapted to the condition of the tools. Once again, Weinig has shown the spirit of innovation here. A fully-automated tool cleaning station with program control takes care of this. At night, during free shifts or at weekends, the wash system takes the relevant tools, cleans them and returns them to the appropriate changeover position. A change of cutter or sharpening is then also problem-free.

Fully automated glazing bead management
The new glazing bead management incorporates the work stage effi-ciently into the entire process of window production. The Powermat formats the scantling and profiles the glazing beads with ship laps in the same throughfeed. The glazing bead is automatically removed at the outfeed and sawn to miter. The bead is then sorted in a carriage and can be fed back into the remaining production process in a sorted condition.
 
New generation of the UniPin gluing and dowel inserting machine
With the new user interface and performance-enhancing process optimization, Weinig is entering the next generation of the UniPin gluing and dowel inserting machine. Whether online in contact with the Conturex or as an individual machine, the new and improved Weinig UniPin is an indispensable CNC system. On a double-leaf window with central pillar and counter-corner or dowel corner joint, at least 56 dowels can be inserted. This means a daily capacity of 1,120 dowels with 20 windows. And all with consistent quality and, crucially, precisely the same glue amount and insertion depth. Only thus can high-quality connection of window corners be guaranteed. The new generation is equipped with new, rapid controls and optional double part processing. In addition, a significantly improved user interface has been developed.

New: "Block gluing" production concept
The Weinig Concept business unit specializes in project planning of complete production lines. A current project will be presented at LIGNA as an example. Visitors to the Weinig stand will be able to learn everything about the project from planning to installation of the system. The system solution comprises an innovative production process for central layers. Weinig has patents and patents pending on the "block gluing with butt joints" process. With this process, Weinig is setting standards in efficient use of resources. Whether planing, gluing, cross-cutting or ripping, technologies are used that create significant savings and higher wood recovery. Block gluing is also more reliable and far less expensive than conventional processes. The added value potential starts with the round timber cutting as block gluing allows the use of a range of sawn timber dimensions with the same end product.

The high flexibility of the system also opens up a range of other products, starting from the glued block, including top layers, shafts for timber construction, CLT profile lamellae and even door frame blanks. The cen-terpiece of the system, the ProfiPress C, presses the glued butt-jointed strand without height offset and with perfect alignment in length. The ProfiPress C is designed for special application as a cold press and, thus, requires no energy for glue hardening. With excellent pressing force distribution, the required adhesive volume can be reduced to a minimum.

New: Standard Weinig user interface
The new standard user interface for all Weinig machines will be shown for the first time at LIGNA. The interface has been developed to offer the user consistency in operation and menu navigation across the entire Weinig product portfolio. This means that the individual machines and software applications create a perfect unit that works together optimally. The intuitive operation is easy to learn. At LIGNA, the new user interface will be on display with optimizing cross-cut saws from the Dimter Line and Optipal packer software.

One-man panel production with the ProfiPress L II
The new Weinig ProfiPress L II is primarily aimed at ambitious workshop businesses and is designed for one-man panel production. The degree of automation of a machine is the basis of personnel efficiency. Both the positioning of the glued lamellae and transfer of the lamellae from the gluing station to the infeed belt or infeed chain are automatic. The pres-sure cylinders are also selected automatically.

Cutting solutions: intensive upgrade
The extensive Dimter Line range of cross-cut saws from Weinig has been enhanced with a range of improvements and extensions in time for LIGNA. The new OptiCut 250 – which will be on the stand in Hanover as an inline scanner solution with the new EasyScan+ – benefits from the consistent evolution of the Performance Series. A new design, new and larger touch-screen user interface and performance-optimized machine concept all enhance the attractiveness of this range. For the OptiCut S 50 Window, the alignment aid for packages in the infeed table is also now available. The proven option of the OptiCut S 90 series provides for increased length accuracy and process reliability.

The options for workpiece recognition have also been extended for models from the OptiCut S 50, OptiCut S 90 and OptiCut 450 FJ+ series. The range now extends from simple recognition of workpieces to appli-cation of high-definition graphic logos even at high feed speeds in the outfeed of an OptiCut 450 Quantum or FJ+. In addition to the increased degree of automation, the advantages lie in optimal process reliability and value creation.

Also at LIGNA, a system solution will be exhibited for the first time that builds upon the OptiCut S 90 Speed. This cross-cutting system achieves performance that can otherwise only be achieved by throughfeed saws while also impressing with its high length accuracy.

The Technology Offensive also extends to the OptiCut 450 FJ+. The new VarioStroke technology makes the saw cut not only faster but also more rigid and flexible. The new technology (patent pending) impresses with cutting times from 65 ms and with unprecedented cutting quality. With VarioStroke, fixed cutting heights and cutting cycle times with high-speed optimizing cross-cut saws are a thing of the past. The servo sawing unit instantly creates the shortest cutting cycle for every timber cross-section; a performance feature that should not be under-estimated with cutting frequencies over 200 cuts/min.

Profitable cutting with the new ProfiRip 340
The completely newly developed multi-blade buzz saw offers up to 3-fold blade adjustment and is designed for high wood recovery. A significant role is played by the integrated TimberMax 3.0 software for optimized cross-cutting and quality pre-cutting. Cutting lists can be maintained and machine diagnostics performed via the RaiNet network connection from the comfort of an office.

New: RipAssist Pro width optimization
The proven RipAssist optimization program for automatic width optimization of boards now offers even better performance. In the enhanced "Pro" version, the board width is now automatically measured with trimmed goods. The software itself has been given an upgrade and can now also optimize combinations of fixed arbor setups (several fixed saw blades) and adjustable saw blades.  It is now also possible to take into consideration variable strip widths. This means even greater material yields. Automatic measurement also increases productivity. The new RipAssist Pro can been seen at LIGNA along with the VarioRio 310 multi-blade rip saw.

Optimal value creation: ProfiRip 450 Speed with CombiScan
Profit maximization and quality start with cutting optimization. At LIGNA, Weinig will be demonstrating its expertise in this process with a high-end system consisting of a ProfiRip 450 Speed rip saw and a Weinig Com-biScan scanner.  The ProfiRip 450 Speed with roller feed is designed for speeds up to 160 m/min. It has 4-fold blade adjustment and a saw shaft with outboard bearing. Pneumatic clamping ensures tool-free operation.

New generation of the CombiScan
The second generation of the CombiScan, Weinig's top scanner model, also celebrates its premiere in this LIGNA year. The new model includes the "Evo" addition and is most notable for its optimized detection performance. This is primarily attributable to new, high-performance cameras, which use higher resolutions to detect small wood defects even at high throughput speeds. As a result, pin knots and other small defects can be detected with ease. Remaining consistently faithful to the principle that the more information, the better the scanning results and the higher the timber yield, the CombiScan Evo now uses up to 3 cameras per side. For defects in the interior of the wood, the scanner can also be equipped high-performance X-ray sensors.

Increased options with the front-end scanner
This innovation scans the front side of the board after cutting at the saw. In planed timber in particular, this makes it possible to differentiate individual qualities according to internal pith. Incorrectly cross-cut parts can also be detected and removed. This produces a reduced error rate in downstream processes, such as finger jointing or processing with double-end machines. The front-end scanner can be retrofitted to the saws at any time.

Top quality thanks to GlueEye glue application detection system
GlueEye offers visual inspection of glue application for HS systems. The current glue application is compared for coverage with a prepared master image using color cameras. Lamellae with defective gluing are indi-cated on the touch panel and rejected based upon defined tolerances. The finger-jointing line stops after a pre-selected number of successive defective gluings.

New generation of long-timber finger-jointing lines
The new generation of Weinig's long-timber systems will be presented via animation at LIGNA. The concept is scheduled for market launch in the near future.

Double-end tenoner: Next stage of evolution for the ProfiShape
At LIGNA 2013, the premiere of Weinig's ProfiShape captured the lime-light. Two years later, the double-end tenoner will be back on the stand in the next stage of its evolution. The customer system on show has magazine charging that can be swung away and is set up for 50 parts/min to create a tongue and groove profile. The machine is equipped with 2 trimming units and 3 milling units on each milling side. The motorized adjustment of the right-hand machine side achieves higher machine availability. Automatic chain cam control changes the cam distances according to the material width. The servo positioning that adjusts itself to the material thickness is also automatic.

Weinig app with added value
The Weinig App-Suite combines information and convenience on a new level for the wood expert. The app's multiple uses offer a decisive ad-vantage over others on the market. The user can find functions for angle calculations, residual length calculations for edge gluing and a cuttermark calculator. A highlight is the tagging and commenting on photos and videos. There are also further helpful functions in the Service area of the App-Suite. At the tap of a finger, the customer can view his entire Weinig machine fleet. Another tap on the phone and he can be taken straight to his requested contact partner. It is just as easy to access the "Machine monitor", where customers can see extensive information about the readiness for operation of their machinery  - wherever they are.

To see photos, visit this site on the press portal.