Bystronic glass: Quick production of triple insulating glass units

The Bystronic glass speed’line celebrated its debut at glasstec 2012. The production line consists of two tps’applicator components arranged one after the other, the new speed’assembler for the quick assembly and gas-filling of insulating glass units as well as the speed’sealer sealing robot.

The high (60 percent) and increasing proportion of triple insulating glass in Germany (Source: "Bundesverband Flachglas" [Federal Flat Glass Association] forecast for 2012) is forcing insulating glass manufacturers to adjust their production processes according to the demand. Three work steps are decisive with regard to the quick production of triple insulating glass units: The application of the spacers, the gas-filling of the spaces between the lites and the sealing of the units. In the speed’line, all three processes are perfectly designed for the production of triple units and enable the quickest cycle times. As a result, the speed’line is able to produce triple insulating glass in the same time it takes other lines to produce double units.

Simultaneous application of two spacers

On the speed’line, the application of the spacers is performed for example by two tps’applicator components arranged one after the other. In order to achieve the maximum throughput, the thermoplastic TPS® warm edge spacers are applied to glass plates 2 and 3 of the triple insulating glass units almost simultaneously. This ensures the continuous and quick supply of glass plates with spacers. As is usually the case with TPS®, the respectively required spacer is applied directly to the glass plate – no separate pre-production or provision of suitable spacers is required. The material from the drum is applied as a strand at approximately 120 degrees Celsius in a patented and proven process. As a result, this permits a real, order-based production without any time losses, without having to divide the orders into standard and special formats or without having to subsequently sort the units. Even changing shapes and formats with different spaces between the lites does not influence the productivity of the speed’line due to the fact that it performs this without manual interventions and equipping times. All required actions are fully-automatic and are triggered by the production data that has been stored in advance.

Simultaneous filling of both spaces between the lites with inert gas

Bystronic glass presented the newly-developed speed’assembler for the quick assembly, gas-filling and pressing of units for triple insulating glass production for the first time at its trade fair stand. Previously, the gas-filling of both of the spaces between the lites of triple units was performed sequentially: the first space between the lites was filled with inert gas first and the second space followed. The new speed’assembler is the first unit to simultaneously fill both of the spaces between the lites on triple units with inert gas. This is beneficial to the cycle time as it reduces the filling time for each unit by half. This is made possible by an optimised filling technology that works with twice as many gas dosing units than has generally been the case to date. The gas filling is performed via a filling gap on the fixed press plate and a second filling gap on the mobile press plate. In doing so, the centre glass plate is constantly supported in order to prevent heavy glass plates from sliding. This new filling technology is present upon the inlet and outlet sides respectively in the tandem version of the speed’assembler. As a result, it is possible to simultaneously create two gas-filled triple insulating glass units. In addition to TPS® insulating glass units, it is also possible to process units with conventional or flexible spacers with the new filling technology in the speed’assembler.

Quickly and flexibly seal in two cycles

The speed’sealer makes the quick and flexible sealing of triple insulating glass units in two cycles possible in the last stage of insulating glass production. This ensures that no equipping times are required to exchange nozzles, even when producing units with alternating or asymmetric spaces between the lites. At glasstec 2010, the speed’sealer was the first component of the speed’line that was presented in the top secret area to a selected audience in advance. The general public will be able to see it for the first time as part of the quick speed’line insulating glass line at this year's glasstec. The core of the speed’sealer is its dynamic mixer. In contrast to the static mixers that are very common in the sector, this mixer works with a significantly reduced material pressure. With a flow rate of six litres per minute, it also makes the utmost material volume available. As a result, it is able to seal even deep spacer setbacks of rectangular units and model formats considerably quicker than other robots. What also sets it apart from other sealing robots is its automatic material changing system that permits an operator-free changing of the sealing material – from polysulphide to silicone for example – inside two minutes.

About Bystronic glass

Bystronic glass symbolizes innovation with machinery, plants, systems and services for glass processing focussed on tomorrow’s market. From basic requirements through to entire, customized installations Bystronic glass provides pioneering solutions – naturally, all in the highest quality. Bystronic glass supplies its well-proven machine technologies also in important areas of the photovoltaic industry. Bystronic glass is an international brand with globally operating companies that support their customers on site and through own sales and service companies. Since 1994, Bystronic glass is part of the Conzzeta AG, a renowned Swiss industrial holding company.