Energy-saving machining method for broken bridge aluminum doors and windows

Abstract

The invention relates to the technical field of door and window manufacturing, in particular to an energy-saving processing method for broken bridge aluminum doors and windows, which reduces the generation of waste materials through an intelligent discharging system, saves raw materials, and indirectly reduces the energy consumption in the links of subsequent processing, carrying, waste material treatment and the like. Dynamic power adjustment is adopted, so that the power of the motor is automatically reduced in a non-load state, and invalid energy consumption can be reduced in the cutting and rolling processes. The heat energy is intensively acted on a required area by utilizing a local heating and curing technology, so that the heat energy utilization efficiency is greatly improved; the situation that the equipment operates at high load at the same time is reduced through full-process energy consumption monitoring and scheduling, and the energy peak value requirement is lowered. According to the energy-saving machining method for the broken bridge aluminum doors and windows, intelligent discharging, power dynamic adjustment, local heating and curing and full-process energy consumption monitoring and optimal control are introduced, so that the machining efficiency is improved, and energy consumption is remarkably reduced.

Description

Technical Field

[0001] This invention belongs to the field of door and window manufacturing technology, and specifically relates to an energy-saving processing method for thermally broken aluminum doors and windows. Background Technology

[0002] Thermally broken aluminum windows and doors are energy-saving window and door structures made of aluminum alloy profiles and thermal insulation materials. They are named for the "thermal break" structure created by adding a thermal break strip in the middle of the aluminum profile. Thermally broken aluminum windows and doors are widely used in residential, office, and commercial buildings. Their structure mainly includes an aluminum profile shell, thermal break strip, glass, sealing strip, and hardware. The aluminum profile shell is made of extruded aluminum alloy, with a surface treated by spraying or anodizing, providing high strength and corrosion resistance. The thermal break strip typically uses low thermal conductivity materials such as PA66 nylon or PVC to separate the inner and outer layers of the aluminum profile, blocking the heat conduction path.

[0003] Currently, the processing of thermally broken aluminum windows and doors mainly involves assembling standardized profiles with insulated glass systems. The entire window manufacturing process is completed through mechanized material cutting, thermal break strip insertion, mechanical rolling or glue injection fixing, corner splicing, hardware installation, and sealing testing. For example, Chinese invention patent CN111633409B discloses a manufacturing machine and method for thermally broken aluminum glass windows and doors. The machine places a U-shaped thermally broken aluminum profile glass window and door frame on a clamping top rod. The clamping top rod moves downwards, and through a clamping connecting rod and a clamping push rod, it drives a clamping push block to move within a clamping track. This clamping block clamps and fixes the U-shaped thermally broken aluminum profile glass window and door frame. Then, the clamping cylinder is activated, causing an L-shaped locking rod to engage with the clamping slot at the lower end of the clamping top rod. This avoids the risks of forcibly inserting the glass, which can lead to scratches or even breakage, posing danger to workers and causing economic losses.

[0004] Our company has disclosed a high-efficiency installation process for thermally broken aluminum alloy doors and windows (CN115070439B). This process divides the traditional single-person installation of thermally broken aluminum doors and windows into multiple procedures and workstations. With the division of labor, each person is responsible for a specific task, which reduces the training time and difficulty for new workers, increases the use of automated equipment, reduces the labor intensity of workers, and improves work efficiency.

[0005] The upstream processing methods described above require the use of large-scale automated machinery, resulting in significant equipment investment and relatively high energy consumption. Furthermore, existing processing methods suffer from the following problems: high energy consumption when equipment is idle, lack of optimized processing sequence, high energy consumption during curing processes, and a lack of real-time energy consumption monitoring. For example, cutting machines, rolling mills, and adhesive curing equipment often operate under idle conditions with constant power, leading to substantial energy waste. Additionally, profiles from different orders cannot be uniformly arranged, resulting in a high rate of cutting waste.

[0006] Optimizing existing thermal break aluminum window and door processing technology, reducing production costs, and promoting energy conservation and carbon emission reduction in manufacturing workshops have become urgent issues to be addressed. Summary of the Invention

[0007] To address the aforementioned shortcomings of existing technologies, this invention aims to solve the problems of high idle energy consumption of equipment, lack of optimized processing sequence, high energy consumption of curing processes, and lack of real-time energy consumption monitoring in current thermally broken aluminum window and door processing methods. This invention provides an energy-saving processing method for thermally broken aluminum windows and doors by introducing intelligent material arrangement, dynamic power adjustment, localized heating and curing, and full-process energy consumption monitoring and optimization control, thereby achieving improved processing efficiency and significantly reduced energy consumption.

[0008] This invention adopts the following technical solution: an energy-saving processing method for thermally broken aluminum doors and windows, comprising the following steps:

[0009] S1. Import profile demand information from multiple customer orders into the intelligent nesting system, run an optimization algorithm based on the order data to generate the optimal cutting layout plan, and reduce the length and quantity of leftover material; the optimization algorithm steps are as follows:

[0010] T1. Initialization: Import all order profile requirement data to form the initial state S0. At this time, there is no cutting and all orders are pending processing.

[0011] Add S0 to the OPEN list and leave the CLOSED list empty. Set the maximum search depth to ensure the real-time performance of the algorithm in industrial applications.

[0012] T2. Select the state node n with the smallest cost function value from the list of open nodes. State node n is the set of currently completed cutting schemes and the remaining uncut orders, i.e.:

[0013]

[0014] If n is the target state (all orders have been cut), the algorithm terminates and outputs the optimal material layout plan;

[0015] T3. Based on the current state n, select one or more profiles from the remaining uncut orders to attempt cutting, and generate a new candidate cutting scheme succ(n). Each subsequent state corresponds to an extension of the cutting layout scheme.

[0016] T4. Calculate the actual cost g(succ), where g(succ) is the total length or quantity of scrap generated by all cut profiles in the current state:

[0017]

[0018] Where k is the number of profiles that have been cut, waitste iLet be the length of the waste material generated from the cutting of the i-th profile;

[0019] Estimate the heuristic cost h(succ), and estimate the minimum possible waste based on the remaining orders and profile length;

[0020]

[0021] Where: R(succ): the set of remaining uncut orders;

[0022] l j : Length of the j-th uncut order;

[0023] L: Maximum usable length of the profile;

[0024] Estimate the number of remaining cutting batches;

[0025] T5. If the successor state succ is not in CLOSED and its f(succ) value is better than the existing record of the same state, then add it to the OPEN list; move the current state n into CLOSED to avoid duplicate expansion.

[0026] T6. Return to step T2 and continue expanding and searching until the optimal solution is found;

[0027] S2. The optimization scheme is transmitted to multiple dedicated CNC cutting machines via industrial bus or wireless communication. Each CNC cutting machine processes profiles of specific length and within the range of tool requirements. The cutting machine completes batch cutting of multiple orders, cuts off and processes corners according to the optimization scheme, reducing energy waste caused by multiple tool changes and repeated positioning.

[0028] S3. Mill the ends of the profile to create connecting tenons and mounting grooves. The thermal insulation strip is then automatically rolled and assembled into the aluminum profile.

[0029] S4. Insert nylon thermal insulation strips into the profile to form a thermally broken structure, ensuring thermal insulation performance.

[0030] S5. After corner jointing, apply adhesive to the joint using an infrared directional heater to heat only the joint. The temperature is controlled at 45–60℃, and real-time temperature monitoring is used to avoid overheating and ensure that the adhesive cures quickly and evenly.

[0031] S6. Install hardware accessories such as hinges, handles, and locks;

[0032] S7. Install the sealing strip into the preset groove to ensure airtightness and watertightness;

[0033] S8. Install the glass, securing it with adhesive strips or pressure strips;

[0034] S9. Spraying or anodizing treatment improves the corrosion resistance and aesthetics of doors and windows;

[0035] S10. Inspect the dimensional accuracy, opening flexibility, sealing performance, and heat insulation performance of doors and windows. After passing the inspection, package the finished products.

[0036] According to another embodiment of the invention or any of the foregoing embodiments, in the energy-saving processing method, the profile requirement information in step S1 includes cross-sectional specifications, length, quantity, color, and surface treatment requirements.

[0037] According to another embodiment of the invention or any of the foregoing embodiments, in the energy-saving processing method, in steps S2 and S3, a power sensing module is installed on the main drive motor of the cutting machine and the heat insulation strip rolling machine to detect the motor load in real time; when it is detected that the cutting machine has cut to the end or is running unloaded, causing the resistance of the tool to cut the profile to decrease, the control system automatically reduces the motor speed and power output; in the rolling machine, when the resistance of the heat insulation strip enters the profile and reaches a stable state, the system maintains a moderate pressure to avoid excessive energy consumption and profile damage caused by excessive pressure.

[0038] According to another embodiment of the invention or any of the foregoing embodiments, the energy-saving processing method includes arranging a multi-functional energy consumption acquisition module at the power input end of the cutting machine, rolling machine, corner assembly machine, and heating curing equipment to collect data such as current, voltage, power, and running time.

[0039] The data acquisition module transmits real-time energy consumption data to the central control platform via a wireless communication module and stores it in the database;

[0040] The central platform automatically arranges the processing sequence based on real-time energy consumption data and current production tasks to achieve off-peak operation;

[0041] Allocate available power limits to different devices based on task priority to avoid energy waste and grid impact caused by instantaneous high load.

[0042] The beneficial effects of this invention are:

[0043] This invention discloses an energy-saving processing method for thermally broken aluminum windows and doors. The intelligent material feeding system reduces waste generation, saving raw materials and indirectly reducing energy consumption in subsequent processing, handling, and waste disposal. Localized heating and curing technology concentrates heat energy on the required area, significantly improving heat utilization efficiency. Dynamic power adjustment automatically reduces motor power under off-load conditions, minimizing ineffective energy consumption during cutting and rolling processes. Full-process energy consumption monitoring and scheduling reduces simultaneous high-load operation of equipment, lowering peak energy demands. Attached Figure Description

[0044] Figure 1 This is a schematic flowchart of the energy-saving processing method for thermally broken aluminum doors and windows according to the present invention; Detailed Implementation

[0045] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0046] like Figure 1 As shown, an energy-saving processing method for thermally broken aluminum windows and doors includes the following steps:

[0047] S1. Import profile demand information from multiple customer orders into the intelligent nesting system, run an optimization algorithm based on the order data to generate the optimal cutting layout plan, and reduce the length and quantity of leftover material; the optimization algorithm steps are as follows:

[0048] T1. Initialization: Import all order profile requirement data to form the initial state S0. At this time, there is no cutting and all orders are pending processing.

[0049] Add S0 to the OPEN list and leave the CLOSED list empty. Set the maximum search depth to ensure the real-time performance of the algorithm in industrial applications.

[0050] T2. Select the state node n with the smallest cost function value from the list of open nodes. State node n is the set of currently completed cutting schemes and the remaining uncut orders, i.e.:

[0051]

[0052] If n is the target state (all orders have been cut), the algorithm terminates and outputs the optimal material layout plan;

[0053] T3. Based on the current state n, select one or more profiles from the remaining uncut orders to attempt cutting, and generate a new candidate cutting scheme succ(n). Each subsequent state corresponds to an extension of the cutting layout scheme.

[0054] T4. Calculate the actual cost g(succ), where g(succ) is the total length or quantity of scrap generated by all cut profiles in the current state:

[0055]

[0056] Where k is the number of profiles that have been cut, waitste i Let be the length of the waste material generated from the cutting of the i-th profile;

[0057] Estimate the heuristic cost h(succ), and estimate the minimum possible waste based on the remaining orders and profile length;

[0058]

[0059] Where: R(succ): the set of remaining uncut orders;

[0060] l j : Length of the j-th uncut order;

[0061] L: Maximum usable length of the profile;

[0062] Estimate the number of remaining cutting batches;

[0063] T5. If the successor state succ is not in CLOSED and its f(succ) value is better than the existing record of the same state, then add it to the OPEN list; move the current state n into CLOSED to avoid duplicate expansion.

[0064] T6. Return to step T2 and continue expanding and searching until the optimal solution is found;

[0065] S2. The optimization scheme is transmitted to multiple dedicated CNC cutting machines via industrial bus or wireless communication. Each CNC cutting machine processes profiles of specific length and within the range of tool requirements. The cutting machine completes batch cutting of multiple orders, cuts off and processes corners according to the optimization scheme, reducing energy waste caused by multiple tool changes and repeated positioning.

[0066] S3. Mill the ends of the profile to create connecting tenons and mounting grooves. The thermal insulation strip is then automatically rolled and assembled into the aluminum profile.

[0067] S4. Insert nylon thermal insulation strips into the profile to form a thermally broken structure, ensuring thermal insulation performance.

[0068] S5. After corner jointing, apply adhesive to the joint using an infrared directional heater to heat only the joint. The temperature is controlled at 45–60℃, and real-time temperature monitoring is used to avoid overheating and ensure that the adhesive cures quickly and evenly.

[0069] S6. Install hardware accessories such as hinges, handles, and locks;

[0070] S7. Install the sealing strip into the preset groove to ensure airtightness and watertightness;

[0071] S8. Install the glass, securing it with adhesive strips or pressure strips;

[0072] S9. Spraying or anodizing treatment improves the corrosion resistance and aesthetics of doors and windows;

[0073] S10. Inspect the dimensional accuracy, opening flexibility, sealing performance, and heat insulation performance of doors and windows. After passing the inspection, package the finished products.

[0074] According to another embodiment of the invention or any of the foregoing embodiments, in the energy-saving processing method, the profile requirement information in step S1 includes cross-sectional specifications, length, quantity, color, and surface treatment requirements.

[0075] According to another embodiment of the invention or any of the foregoing embodiments, in the energy-saving processing method, in steps S2 and S3, a power sensing module is installed on the main drive motor of the cutting machine and the heat insulation strip rolling machine to detect the motor load in real time; when it is detected that the cutting machine has cut to the end or is running unloaded, causing the resistance of the tool to cut the profile to decrease, the control system automatically reduces the motor speed and power output; in the rolling machine, when the resistance of the heat insulation strip enters the profile and reaches a stable state, the system maintains a moderate pressure to avoid excessive energy consumption and profile damage caused by excessive pressure.

[0076] According to another embodiment of the invention or any of the foregoing embodiments, the energy-saving processing method includes arranging a multi-functional energy consumption acquisition module at the power input end of the cutting machine, rolling machine, corner assembly machine, and heating curing equipment to collect data such as current, voltage, power, and running time.

[0077] The data acquisition module transmits real-time energy consumption data to the central control platform via a wireless communication module and stores it in the database;

[0078] The central platform automatically arranges the processing sequence based on real-time energy consumption data and current production tasks to achieve off-peak operation;

[0079] Allocate available power limits to different devices based on task priority to avoid energy waste and grid impact caused by instantaneous high load.

[0080] Working principle of the invention:

[0081] This invention employs an intelligent nesting system to reduce waste generation, saving raw materials and indirectly reducing energy consumption in subsequent processing, handling, and waste disposal. Profile requirement information (including profile cross-sectional specifications, length, quantity, color, and surface treatment requirements) from multiple customer orders is imported into the intelligent nesting system. Based on the order data, the system runs an optimization algorithm (such as heuristic search or genetic algorithm) to generate the optimal cutting layout, minimizing the length and quantity of leftover material. The optimized layout is transmitted to the CNC cutting machine via industrial bus or wireless communication. The cutting machine automatically completes batch cutting of multiple orders according to the optimized path, reducing energy waste caused by multiple tool changes and repetitive positioning. This method can reduce the profile scrap rate from approximately 8% to about 5%, while also reducing idling time during the cutting process and lowering the ineffective operating power of the cutting motor.

[0082] This invention utilizes localized heating and curing technology to concentrate heat energy on the desired area, significantly improving heat utilization efficiency. Full-process energy consumption monitoring and scheduling reduces the occurrence of simultaneous high-load operation of equipment, lowering peak energy demand. Power sensing modules are installed on the main drive motors of the cutting machine and the heat insulation strip rolling machine to monitor motor load in real time. When a decrease in cutting resistance is detected (e.g., cutting to the tail section or running unloaded), the control system automatically reduces motor speed and power output. In the rolling machine, once the heat insulation strip enters the profile and the resistance reaches a stable state, the system maintains moderate pressure to avoid excessive energy consumption and profile damage due to excessive pressure. Testing shows that in typical production tasks, dynamic power adjustment can reduce unloaded energy consumption by more than 20% without negatively impacting processing speed and quality.

[0083] This invention utilizes localized heating curing technology to concentrate heat energy on the desired area, significantly improving heat utilization efficiency. Most existing processes employ full-cavity heating, heating the entire door / window frame during the curing stage. This not only involves a large heating area and high energy consumption but also leads to excessively high surface temperatures on the profiles, affecting the stability of the sprayed coating. This invention uses infrared directional heaters or small electric heating blocks to directionally heat only the adhesive joints at the corners, concentrating heat energy on the adhesive curing area. The heating device monitors the adhesive joint temperature in real time using temperature sensors, maintaining it within the optimal curing range (e.g., 45–60°C) to prevent overheating or under-curing. Compared to full-cavity heating, localized heating can shorten curing time by 50%, reduce curing energy consumption by approximately 40%, and lower the rework rate caused by overheating of the profiles.

[0084] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the above embodiments are merely illustrative of the technical concept and characteristics of the present invention, intended to enable those skilled in the art to understand and implement the invention, and should not be construed as limiting the scope of protection of the present invention. All equivalent changes or modifications made in accordance with the spirit and essence of the present invention should be covered within the scope of protection of the present invention.

Claims

1. A method for energy-saving processing of thermally broken aluminum doors and windows, characterized in that: Includes the following steps: S1. Import profile demand information from multiple customer orders into the intelligent nesting system, run an optimization algorithm based on the order data to generate the optimal cutting layout plan, and reduce the length and quantity of leftover material; the optimization algorithm steps are as follows: T1. Initialization: Import all order profile requirement data to form the initial state S0. At this time, there is no cutting and all orders are pending processing. Add S0 to the OPEN list and leave the CLOSED list empty. Set the maximum search depth to ensure the real-time performance of the algorithm in industrial applications. T2. Select the state node n with the smallest cost function value from the list of open nodes. State node n is the set of currently completed cutting schemes and the remaining uncut orders, i.e.: If n is the target state (all orders have been cut), the algorithm terminates and outputs the optimal material layout plan; T3. Based on the current state n, select one or more profiles from the remaining uncut orders to attempt cutting, and generate a new candidate cutting scheme succ(n). Each subsequent state corresponds to an extension of the cutting layout scheme. T4. Calculate the actual cost g(succ), where g(succ) is the total length or quantity of scrap generated by all cut profiles in the current state: Where k is the number of profiles that have been cut, waitste i Let be the length of the waste material generated from the cutting of the i-th profile; Estimate the heuristic cost h(succ), and estimate the minimum possible waste based on the remaining orders and profile length; Where: R(succ): the set of remaining uncut orders; l j : Length of the j-th uncut order; L: Maximum usable length of the profile; Estimate the number of remaining cutting batches; T5. If the successor state succ is not in CLOSED and its f(succ) value is better than the existing record of the same state, then add it to the OPEN list; move the current state n into CLOSED to avoid duplicate expansion; T6. Return to step T2 and continue expanding and searching until the optimal solution is found; S2. The optimization scheme is transmitted to multiple dedicated CNC cutting machines via industrial bus or wireless communication. Each CNC cutting machine processes profiles of specific length and within the range of tool requirements. The cutting machine completes batch cutting of multiple orders, cuts off and processes corners according to the optimization scheme, reducing energy waste caused by multiple tool changes and repeated positioning. S3. Mill the ends of the profile to create connecting tenons and mounting grooves. The thermal insulation strip is then automatically rolled and assembled into the aluminum profile. S4. Insert nylon thermal insulation strips into the profile to form a thermally broken structure, ensuring thermal insulation performance. S5. After corner jointing, apply adhesive to the joint using an infrared directional heater to heat only the joint. The temperature is controlled at 45–60℃, and real-time temperature monitoring is used to avoid overheating and ensure that the adhesive cures quickly and evenly. S6. Install hardware accessories such as hinges, handles, and locks; S7. Install the sealing strip into the preset groove to ensure airtightness and watertightness; S8. Install the glass, securing it with adhesive strips or pressure strips; S9. Spraying or anodizing treatment improves the corrosion resistance and aesthetics of doors and windows; S10. Inspect the dimensional accuracy, opening flexibility, sealing performance, and heat insulation performance of doors and windows. After passing the inspection, package the finished products.

2. The energy-saving processing method for thermally broken aluminum doors and windows according to claim 1, characterized in that: In step S1, the profile requirements include cross-sectional specifications, length, quantity, color, and surface treatment requirements.

3. The energy-saving processing method for thermally broken aluminum doors and windows according to claim 1, characterized in that: In steps S2 and S3, a power sensing module is installed on the main drive motor of the cutting machine and the heat insulation strip rolling machine to detect the motor load in real time. When the cutting machine is detected to have cut to the end or to be running unloaded, causing the resistance of the cutting tool to cut the profile to decrease, the control system automatically reduces the motor speed and power output. In the rolling machine, when the resistance of the heat insulation strip enters the profile and reaches a stable state, the system maintains a moderate pressure to avoid excessive energy consumption and profile damage caused by excessive pressure.

4. The energy-saving processing method for thermally broken aluminum doors and windows according to any one of claims 1, 2, and 3, characterized in that: Multifunctional energy consumption acquisition modules are installed at the power input terminals of cutting machines, rolling machines, corner assembly machines, and heat curing equipment to collect data such as current, voltage, power, and running time. The data acquisition module transmits real-time energy consumption data to the central control platform via a wireless communication module and stores it in the database; The central platform automatically arranges the processing sequence based on real-time energy consumption data and current production tasks to achieve off-peak operation; Allocate available power limits to different devices based on task priority to avoid energy waste and grid impact caused by instantaneous high load.

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