Wood Division
Pro Evolution Systems
CMS has helped to rethink the way that window and door components are constructed, and the Pro Evolution system is a result of this “reindustrialization” of particular strategic market segments. The Pro Evolution system (Patent Pending) allows for the manufacture of doors and windows across a wide range of demands in terms of materials and part types.
The Pro Evolution system is composed of a fixed bridge structure, inline flow, with enclosure for safety. The system offers a small footprint, low energy expenditure, with high accuracy. The finish of a component part machined by the Pro Evolution system has high integrity with limited blowout or burrs. Clean, blemish free surfaces are especially important in window frame and door millwork.
The typical production line for windows and doors consists of combining different machines, each specialized in a single operation of the whole working process, yet creating very complex batch management requirements as well as taking up large floor space.
CMS' Pro Evolution is a truly innovative design and universal production capability, a machining center complete with automatic piece loading / unloading and handling systems which transforms a wooden blank into a finished lineal part of a window or door. The system can work unattended and without retooling even in one-off production requirements.
The result is a complete production line, very compact in size and with a much lower energy consumption compared to other solutions on the market.
Besides being fully automated and totally flexible, Pro Evolution provides a superior finish quality, because the piece needs no repositioning, the whole machining cycle has already been finished when it is ready to move on to assembly clamp and then to finishing.
The Pro Evolution system delivers such high accuracy because the machining processes are driven by barcode. When a part arrives the barcode is read, and the Pro Evolution machine divides up each task according to the required instructions. Such advanced digital processing technology means that accuracy is achieved to at a superior level. Accuracy is also assured with Pro Evolutions' advanced technologically for part holding and clamping. Pro Evolution's patented clamping device clamps the blank and does not release it until the part is completely machined. No repositioning of the part means no inaccuracies.
For companies with expansion on the horizon Pro Evolution is scalable; and as the requirement grows for complexity and output Pro Evolution can be expanded. To provide for that growth Pro Evolution is offered in models 1, 2 and 3. Consider a window frame of 1300 x 1400 mm, with a double opening window (12 pieces in all, pre-finished), machining of profiles and counter-profiles, glazing bead machining and retention with frame part, drilling for dowels, dowel insertion, drilling for hinges and knob seats. The PE1 completes 46 typically sized pieces per hour, the PE2 completes 90 pieces per hour, and the PE3 completes 124 pieces per hour.
Pro Evolution's high productivity is achieved as a result of its high axes speeds, the absence of setup times, and the geometrical design of it complete system. Pro Evolution's wide choice of machine configurations and interfacing capability along with the customer’s programming and management software makes Pro Evolution easily adaptable to each customer’s specific production requirement.
Advantages of the CMS Pro Evolution:
- Great productivity combined with compact size and reduced energy consumption
- High accuracy and superior finishing quality
- Excellent flexibility with the possibility of machining one-off components
- Patented systems for clamping of blank components and machining of the glazing bead
- Highly effective extraction system
- Perimeter enclosure for operator and environment protection
- Fully automated management of in-feed blank dimensions and all installed tooling
- Interfacing with management systems, automatic program generation, automatic program launching via bar code reader
- Up to 128 tools
- Productivity prefinished part: up to 124 pieces/hour on Pro Evolution 3
- Patented system for glazing bead machining
- Device for checking electrospindle vibration and loss of balance: fitted onto the electrospindles it checks for vibration and loss of balance (i.e. to verify possible tool or blade breakage)
- Dowel pin insertion unit
- GSM telephone dial (SIM CARD not included) to send the Production Manager text messages about the main emergency alarms
- Piece repositioning system for the automatic machining in pre-finished mode (for pieces up to 1,700 mm long to be worked in pairs). Only required for Pro Evolution 1
The Pro Evolution system has many options as well as finishing operations that can be integrated into it based on each customer’s requirement. CMS' philosophy of providing solutions for each customer’s requirement based on our decades of engineering and problem solving experience results in customer satisfaction. It’s a way of doing business that means CMS can configure a Pro Evolution system that will meet your window frame and passage door component needs.
Pro Evolution - Machine
Pro Evolution - the production line with unique advantages. Pro Evolution has a fixed bridge structure ensuring maximum machining stability and superior finishing quality. Pro Evolution's unique patented clamps have a very stiff structure, come with NC- controlled clamping pressure, allow for differentiated clamping force depending on the hardness and resistance of the wood to be machined and make possible the machining of all sides of the component, without removing the part. Pro Evolution also takes advantage of independent working spindles so that tool changing times are masked. Pro Evolution comes in three versions with 1, 2 or 3 fixed bridges depending on the production capacity required and complexity of the work to be carried out.
Overview of a Pro Evolution 2 from the infeed end
An overview of a Pro Evolution 2 from the infeed end. Parts are placed crosswise to the infeed belts. Various part sizes or even part types can be placed on the belt at the same time. As each part enters the machine, its barcode label is read to determine if the actual part being fed into the machine matches the part size indicated on the barcode label. Then the information regarding all the operations to be performed is automatically managed and distributed to the various working areas of the line by Pro Evolution's on-board management software, which divides up the required operations to be performed as indicated by the barcode label information. Although it's possible for Pro Evolution to machine parts from different cutting tool families in a random fashion, it is always best for efficiency's sake to manage a production window and group like cutting tool families of parts together to avoid wasted time.
Overview rendering of Pro Evolution 1 without the protection enclosures
An overview rendering of Pro Evolution 1 without the protection enclosures showing the infeed belts in red, the fixed bridge in gray, and the outfeed belts in green. Between the infeed and outfeed Pro Evolution under CNC control scans each part's barcode, check to make sure the part corresponds to the barcode dimensional information, distributes the work to be done to the various machining modules in the line, positions the part correctly to be grasped by the patented and individually CNC controlled clamping units, moves each part precisely and rapidly to the various high performance working units to carry out the required machining processes on both ends and one long side during the first pass through the line, and exits the part at the end of the process. If the parts are to be pre-finished (that is with a machined finished on all 4 sides and for required fittings ultimately) those parts are returned after the first pass to the infeed again and the remaining long side is finished in a second pass through the machine. In such a manner, the Pro Evolution 1 configuration with a TX3 and PX5 head (5 axis type) on its one fixed bridge will produce a window frame of 1300 x 1400 mm, with double opening windows, composed of 12 pieces, as follows: 1 completely pre-finished piece every 78 seconds on average, i.e. 46 pieces per hour or 30 windows in 8 hours.
In addition the following features are shared by Pro Evolution versions 1, 2 or 3:
Piece width: from 40 to 250 mm
Part Thickness: from 20 mm to 90 mm (from 50 to 160 mm on request)
Length: from 180 mm (profile end) up to 3,700 (blank outer profile) – up to 6,000 mm on request
Machining cycle of pieces in pairs: pieces have the same length (up to 1,700 mm) and cross sectional dimension, namely pairs of stiles or rails.
Pieces longer than 1,700 mm or pieces which cannot be put together (odd pieces or i.e. trapezoidal window) are machined one by one.
Overview rendering of Pro Evolution 2
An overview rendering of Pro Evolution 2; its protection enclosures not showing. The infeed belts are in red, the fixed bridges are in gray, and the outfeed belts are shown in green.
As mentioned in the preceding comments regarding the Pro Evolution 1, Pro Evolution 2 carries out the same approach to the work with the exception that it passes the part after the machining on both ends and one side has been completed to another set of Pro Evolution's patented CNC controlled clamps. During this operation the part is never released by the first set of clamps until the second set of clamps has securely taken hold of the part being machined, which means there is no intermediate handling inaccuracy possible due to part repositioning. On Pro Evolution 2 following the reading of the barcode, the various operations are divided up and distributed to the working units on the 1st and 2nd fixed bridges, which in the recommended configuration each has a TX3 and PX5 (5 axis type) head and the time per part is thus reduced.
The Pro Evolution 2 in the above configuration will produce a window frame of 1300 x 1400 mm, with double opening windows, composed of 12 pieces, as follows: 1 completely pre-finished piece every 40 seconds on average, i.e. 90 pieces per hour or 60 windows in 8 hours.
Note: Pro Evolution 2, as is true for versions 1 and 3, can be equipped with CMS' patented system for glazing bead machining: this special option is used to simultaneously execute all the operations to obtain the window glazing bead and the profile, namely: shaping of inner profile, stapling, upper shaping and cutting of glazing bead. This device is also used to cut the glazing bead ends at 45°, and machine the antitorsion groove at the stiles' ends.
Pro Evolution version 2 shares the same general characteristics as mentioned for Pro Evolution 1.
Pro Evolution 3 in a rendering without its protection enclosures showing
Pro Evolution 3 shown in an overview rendering; its protection enclosures not showing. The infeed belts are in red, the fixed bridges are in gray, and the outfeed belts are shown in green.
Pro Evolution 3 carries out the same approach to the work as Pro Evolution 2 with the exception that following the completion of the work from the 2nd fixed bridge, the part is passed to a 3rd set of Pro Evolution's patented CNC controlled clamps. Again during this operation the part is never released by the clamps holding it until the next set of clamps have securely taken hold of the part being machined, with the result that there is no handling inaccuracy possible due to part repositioning between one set of clamps and the next. As with Pro Evolution 2, after Pro Evolution 3 reads the barcode for the part, the various operations are divided up and distributed to the working units on the 1st, 2nd and 3rd fixed bridges, which in the recommended configuration each has a TX3 and PX5 (5 axis type) head and the time per part is thus reduced even further.
Pro Evolution 3 in the above configuration will produce a window frame of 1300 x 1400 mm, with double opening windows, composed of 12 pieces, as follows: 1 completely pre-finished piece every 29 seconds on average, i.e. 124 pieces per hour or 82 windows in 8 hours. To obtain maximum efficiency, the machining of all 6 stiles for the openers and window frames is carried out first, followed by the 6 rails.
Note: Pro Evolution 3 (as is true for versions 1 and 2) may have an optional dowel pin insertion unit.
This unit is mounted in the finished part unloading area and is used to insert cylindrical dowel pins into previously drilled holes – dowel pin diameter to be advised (but is usually from 8-12 mm). The dowel pin is inserted only at the piece ends (the customer shall advise the type of glue used, pre-glued dowels are also possible with water being injected and not glue). The dowel magazines are able to feed the insertion unit for about 4 hours without refilling. Magazine refill is manual by the operator; magazine minimum level is controlled by a microswitch: a warning message is displayed on the NC video and the 3-colour lamp on the electrical cabinet of the last fixed bridge lights up when a refill is needed.
Pro Evolution version 3 shares the same general characteristics as mentioned for Pro Evolution 1 and 2.
Some specifics on the preceding productivity numbers
Some specifics related to the productivity numbers in the preceding examples based on the drawing for this window frame. Productivity refers to a window frame having two independent opening frames, so there is a total of 12 parts per finished window frame. The basic window frame is 1,300 x 1,400 mm – with a thickness of 69 mm. The parts will be machined with a counter profile and dowel holes, and, when the glazing bead unit option is present, with the machining of the glazing bead, which remains stapled to the part being machined.
The blanks are in laminar pinewood, which is planed and sized to measure, and have a material overage of about 3 mm in length on each end.
The frame profiling is carried out on both sides.
The drilling for the dowel holes is carried out by means of an aggregate with 3+3 horizontal exits, and two drilling passed are executed for each position.
One (1) aggregate with 3 vertical exits is also supplied for drilling the hinge and knob seats.
A shot of Pro Evolution's CNC control
Each fixed bridge in a Pro Evolution line has its own CNC control. Today's new generation high performance electronics are used for the management and motion of the machining center axes to provide for the high quality standards typically expected from CMS. A network card is also provided for establishing an efficient connection with the local corporate network.
Brushless servomotors with full digital converters and transmission guarantee reliability and immunity to interference, as well as high speed and acceleration. Digital technology provides superior quality of movement and machining; and it allows CMS to develop special macro instructions for the optimization of the machining center parameter program to suit each specific type of required machining (roughing, contouring of sharp-edged paths, contouring of complex paths, and so forth).
Pro Evolution's use of integrated barcode reading technology
Pro Evolution's use of smart technology includes its integration of barcode reading, by which it acquires from the customer's corporate network all the required data for processing the part to be machined. Here the operator is using the wireless barcode reading device before placing the part to be machined on the infeed belts, which ensures that there is no information misread from that point forward.
Pro Evolution - Structure & CNC Clamping
Pro Evolution's superior performance is based on its rigidly welded monobloc structure, providing maximum process stability. Its design included the following considerations:
- Use of a cellular (honeycomb) style design made from folded steel plate for high torsional stability.
- Structural dimensioning through finite element computation programs (FEM).
- An FEM design to ensure a high level of stiffness and rigidity with reduced weight, resulting in high accelerations and finish quality.
- Accurate analysis in the design stage of first resonance frequency to ensure vibration free machining.
- Normalizing by heat treatment of all structures to ensure maximum stability.
- All machined surfaces created in one machine set up so as to ensure total accuracy and alignment.
- Large leveling machine supports to ensure ease of alignment and solid anchoring to the floor.
- The highest quality drive systems, hardened and precision ground, giving smooth and precise movement with long-life characteristics.
- Laser systems used during the assembly phase to ensure the highest possible alignment standards: for example, rack/guide parallelism guaranteed to within +/- 0.01 mm.
- Rack and pinion systems specifically oversized to exceed the design life of the machine. Additional durability guaranteed by the use of high-pressure automatic grease lubrication and innovative ball-bearing cage protection systems.
Pro Evolution's high performance working spindles are mounted on one or more fixed bridges placed throughout the line, providing the Y, Z and additional axial movements required. These bridges, called the CMS "High Bridge" style, are unequaled for their cross section and rigidity and are based on an aeronautical structure (honeycomb-like cell), obtained through the assembly of heavy welded section elements. By utilizing folding technology the "High Bridge" minimizes the number of elements required, reducing the number of welded joints and so achieving a greater stiffness and strength.
Pro Evolution's production flow is accomplished by CNC-controlled groups of moving clamps (patented) built on a monobloc basement and provide for its loading, unloading and movement along the X axis capabilities.
Pro Evolution's patented CNC controlled clamping system provides controlled, secure and accurate transfer of the part from one set of clamps to the next, when so configured, to complete the machining on all 4 sides of the part being produced. Pro Evolution's clamping system also makes it possible to machine arches on pre-finished blocks.
Pro Evolution safely clamps short and narrow parts thanks to its very stiff, special clamping system, which is able to clamp various length parts, and can lock in position even the most critical parts, especially those being shorter than the length permitting to place two clamps side by side. The interlacing fingers of the clamps makes it possible to exchange even parts with plane surfaces only 15 mm wide. The release movement of the clamp supporting surface also prevents parts from being scratched while being exchanged to the next set of clamps.
A view of Pro Evolution's
A view of Pro Evolution's "High Bridge" showing two independent CNC controlled carriages each of which has a high performance working spindle. On the left is CMS' TX3 ATC spindle, working in a 3 axis manner, liquid cooled, HSK63E connection, 15 kW (S1) [20 hp] at 12,000 rpm, maximum of 24,000 rpm working with a 24 place tool changing magazine, and can be equipped with a 4th axis device for rotation of mechanical aggregates throughout 360° under CNC control. On the right is CMS' PX5 ATC spindle, working in a 5 axis manner, liquid cooled, HSK63F connection, 12 kW (S1) [16 hp] at 12,000 rpm, maximum of 24,000 rpm working with a 16 place tool changing magazine. Both are equipped with a Balluff chip identification system to ensure that the correct tool is known and selected by the CNC control, thus avoiding human error in tool placement.
Both working units are shown in close proximity to Pro Evolution's patented clamping system where the exchange of a part just finished, and which was held in the left clamping group, has been transferred to the right clamping group.
A close-up of Pro Evolution's base carrying its patented clamping system
A close-up view of the rigid base on which all of Pro Evolution's patented independent CNC controlled clamping devices moves. The base has a side to side CNC controlled movement and the clamping system has an end to end CNC controlled movement. The base also takes advantage of the same design methodology as the "High Bridge".
Pro Evolution transfers a pair of parts from one process to the next
A picture showing a pair of rails (or stiles) being transferred from Pro Evolution's 1st process to its 2nd process (or from its 2nd to its 3rd process). Pro Evolution's ability to hold a pair of parts on which the same operations are carried out (in addition to its ability to hold single parts, whether short or very long) dramatically increases its efficiency and productivity.
Pro Evolution shown transferring a part from one phase to the next phase - 1st photo
Pro Evolution is shown transferring a part finished in one phase to the next phase. Pro Evolution's patented clamping system continues to hold the just finished part, as the next set of clamps moves into position and prepares to clamp the part. The part will not be released by the 1st set of clamps until the 2nd set of clamps has securely clamped the part. In order to obtain a better hold on the part, Pro Evolution's clamps have interlacing fingers machined into them, thus permitting them to move more closely together.
Pro Evolution also controls the clamping pressure exerted on the part surface. The correct pressure can be chosen for each type of material to avoid impressions in the part surface created by too much pressure.
Pro Evolution shown transferring a part from one phase to the next phase - 2nd photo
In this picture the 2nd phase of the transfer is shown. Now the 2nd set of clamps has securely clamped the part, while the 1st set of clamps continues to hold. Notice the interlacing fingers on Pro Evolution's clamps, which allow them to move more closely together.
Pro Evolution shown transferring a part from one phase to the next phase - 3rd photo
In this picture the 3rd phase of the transfer is shown. Now the 2nd set of clamps continues to securely hold the part, while the 1st set of clamps releases its hold on the part and the process can continue to move forward through Pro Evolution.
Pro Evolution's clamp surface cleaning system
Pro Evolution's patented clamping system also makes sure that the clamping surface is free from debris or chips before a clamping cycle takes place to ensure the part is securely and accurately held, and prevents a surface from being marred. Each clamp has on either side a dedicated blowing nozzle to ensure its clamping surface is clean before the process continues.
In addition, all debris or chips which have not been extracted at this point through the dust collection system are allowed to fall down onto Pro Evolution's powered chip take away conveyor belt and can be extracted by the dust collection system from there.
Pro Evolution - Spindles & Tool Storage
To provide for a wide range of styles, a high level of complexity, with maximum power and performance, Pro Evolution's utilizes CMS' TX3 and PX5 working units in one or more locations depending on the version of Pro Evolution in production. Each of these working units is controlled in an independent manner by the CNC control. The TX3 performs 3 axis work with an additional 4-axis, rotating about the Z axis, for mechanical aggregates, having a 15 kW (20 hp), S1 power rating at 12,000 rpm with a maximum speed of 24,000 rpm, liquid cooled. The PX5 performs 5-axis work having a 12 kW (16 hp), S1 power rating at 12,000 rpm with a maximum speed of 24,000 rpm, liquid cooled. In total, Pro Evolution can carry up to 128 tools with a tool max. Ø: 350 mm (13.78"). For the many tools potentially involved, Pro Evolution utilizes the Balluff system for automatic tool management to ensure that each tool is correctly known and its specifications for work are correctly handled during the machining cycle.
In addition, Pro Evolution has a patented multipurpose working unit for machining the window glazing bead including a single bladed stapling unit so that the bead remains with the part having been machined.
A photo of CMS' TX3 spindle
A photo of CMS' TX3 spindle, a heavy, robust, liquid cooled, working spindle of 15 kW (20 hp) at 12,000 rpm with an S1 rating, having an HSK 63E connection and capable of using tools with a maximum diameter of 350 mm (13.78") and length of 302 mm (11.88") from the spindle nose. It also comes equipped, as needed, with an additional 4th axis which rotates about the Z axis through 360° for the use of various mechanical aggregates needed in the machining process. Notice the very large tool which the TX3 is holding. This is a stacked tool arrangement to reduce the number of tools in the magazine and the time for changing out the tool, since the tool that is stacked is required during the same machining process. The TX3 head has a 24 or 40 place chain type magazine from which to select the variety of tools it needs for its work.
A photo of CMS' PX5 working unit
A photo of CMS' PX5 working unit, a powerful and robust, liquid cooled, working spindle of 12 kW (16 hp) at 12,000 rpm with an S1 rating, having an HSK 63F connection and capable of using tools with a maximum diameter of 250 mm (9.84") and length of 302 mm (11.88") from the spindle nose. The PX5 spindle is also capable of working with various mechanical aggregates needed in the machining process. The PX5 head has a 16 place disc magazine from which to select the variety of tools it needs for its work.
Pro Evolution's patented window bead machining group
A view of Pro Evolution's patented window bead machining group. The group carries out its work by machining the 45° angle on the ends of the window bead, then the various spindles required align themselves so that in one pass the machining of the window frame profile and the bead profile are obtained with the bead being stapled to the part being machined so that it stays with that part.
Close-up shot of window bead profile tools
A close-up shot of two of the profile tools involved with machining the window bead.
Photo of one of Pro Evolution's chain magazines
A photo of a 40 place chain type magazine working with Pro Evolution's TX3 working unit. Before work begins for the day, Pro Evolution scans, reads and memorizes the entire group of tools placed in the magazine so that the tools are easily and correctly located when needed in production.
Photo showing a large complex tool held in the chain magazine
An example of a large complex tool being held in the chain magazine ready for use. These tools can have a maximum diameter of 350 mm and 302 mm length from the spindle nose.
Shot of a 16 place tool holding disc
A shot of a 16 place tool holding disc with a variety of tools required for the PX5 working spindle. As with the chain magazine, Pro Evolution scans and memorizes each of the tools in this magazine at the beginning of the day so that the position of each tool is know and quickly available.
Pro Evolution - Examples
The following pictures show a few examples of the work that highlights Pro Evolution's strength in the window frame and passage door industries. Every day Pro Evolution provides the unique capabilities for the complex, the "one-off", the popular – in short the wide variety demanded for today's leading manufacturers.
Pro Evolution is capable of either making all these parts or doing so in combination with other CMS machining centers, or machines already in the customer's manufacturing plant. The parts are either pre-finished and ready to be assembled, or Pro Evolution has finished the internal machining and the parts are then assembled and moved to other machines where the final external machining is carried out. Even when the requirement involves an arch or cord segment in a frame, Pro Evolution can take care of it. Whatever the requirement, a Pro Evolution line alone or in concert with other machines meets today's and tomorrow's window frame and passage door challenges.
Pro Evolution delivers on the details
Today's complex window frame, passage door and door millwork requirements present no challenge to Pro Evolution. Machining complex joints, profiles and beading are all part of what Pro Evolution does including its patented clamping system for holding and transferring small, large, long or tandem parts, its patented "bead glazing" system, coupled with its extreme system rigidity for high quality machine finish, unmatched productivity and delivering production based on batch, "one-off" or volume schedules.
A beautiful corner window
A beautiful corner window
An elegant pivoting arched window-door
An elegant pivoting arched window-door
A beautiful circular window
A beautiful circular window
An expansive sliding glass door arrangement
An expansive sliding glass door arrangement providing privacy and openness as desired.
A massive three story window arrangement with side lights
A massive three story window arrangement with side lights
A chic modern sliding door presentation
A chic modern sliding door presentation