In traditional measurement methods for testing and controlling the geometric dimensions of profiles in the Aluminum profile manufacturing industry (as in other traditional industries), there has been big progress over the last 20 years as a result of advances in the computing field. This includes the hardware, software and networks.
Faster, computerized sensors that operate on different physical principles have increased data processing capacity in previously unknown quantities and speeds, and enabled high-tech companies to develop various measurement systems that provide an advanced and high-quality solution for the aluminum profiles industry. This has enabled measurement results to be shared from the production floor throughout all the relevant departments within the plant, and to do so in real-time and with a higher level of accuracy and speed. This process has been revolutionary. It allowed for significant improvements by reducing production costs, decreasing the number of defects, and optimizing the production efficiency of the Aluminum profile.
In 1994, Romidot was the first company to pioneer a new method for measuring aluminum profiles. We created, developed, and brought to market a technology-based system for image processing, the RomiShape \ AL-A4 model. This system made it possible for the very first time to measure the geometric dimensions of the Aluminum profile cross section, and to do so automatically in a fast, objective and effective manner. This new, revolutionary measurement technology was based on a photograph (using a scan) of the measured sample cross-section. The scan converted the acquired image to an accurate profile contour outputted in a raster format. The contour output of the sample profile was automatically matched and compared to the imported contour of the designed profile (drawing). A results report was generated immediately and was available in either a text-based or graphical format, detailing the complete geometrical dimensions of the measured profile.
Following Romidot, other companies began to develop measuring equipment, some of which was based on image processing, and some of which was based on various sensors (optical or mechanical) that made it possible to provide geometrical dimension reports for the measured profile.
Most of the machines which have been offered to the Aluminum Profile Industry were machines whose method of measurement was based on the specific location of the individual measurement, whether using an optical-cross position in camera-equipped machines, or based on a touch probe in XYZ machines. About 95% of the machines currently offered in the market are stand-alone measuring machines that are not integrated with the production facility’s networks. As a result, these systems do not distribute the required information acquired by the measuring machine to the necessary departments of the plant. The data produced by these types of machines are limited to being stored locally within the machine itself.
What determines the quality of the measurement system and its ability to provide a better solution is its level of sophistication and the capabilities offered by the software applications provided with the machine. Similarly, it is vital that the system is durable enough to be installed in close proximity to the press itself. It must be able to perform continuous work around the clock under the typical, harsh production floor environment and conditions, enduring vast shifts in seasonal temperature and humidity year round while operating without failure.
In this area, too, Romidot leads the industry by providing integrative measurement solutions that allow the information obtained from our systems to flow to all relevant departments in the production plant, providing them the required information in real-time.
Continuous work around the clock in harsh factory conditions and in close proximity to the press is of utmost importance. Lesser quality systems often utilize aluminum mounts. Aluminum is highly reactive to both heat and cold, and even minor changes in these aluminum mounts will cause variations in profile measurement and cutting, thereby increasing errors and driving up costs.
Therefore, our machines are designed to eliminate the effects of varying temperatures, as well as shocks and vibrations, by utilizing planar granite slabs. These granite slabs are equipped with our revolutionary, state-of-the art optical system as well as the paddle system, both of which require surfaces unaffected by temperature and environmental conditions.
Additionally, until now, one limitation common to all measuring machines in the Aluminum and PVC profile industry has been that the information provided is the measurement of dimensions only in a specific location as defined in the measuring program. Therefore, undefined dimensions in the measuring program couldn’t be presented in the results of this specific location. This has long been the situation for small areas or regions which have not been defined in the measuring program due to various limitations.
In addition, there has not been a solution that presents measurement reports of the structure of assembled profiles which allows the Aluminum profile manufacturer to know in advance if the connection points are problematic, and whether the dimensions of the structure, when taking into consideration the ultra-precise fittings of the connection places from one profile to another, are in accordance with the design.
In light of these two issues and the limitations of current industry methods, Romidot has once again, just as in the past, pioneered a brand new solution. We are pleased to present our exclusive, proprietary technology which is the ultimate and absolute solution to allow Aluminum profile manufacturers to raise the level not only of quality but also efficiency in the production process of aluminum profiles.
Romidot’s Virtual Gauge – This is a brand new, unique application for complete verification of all profile dimensions and shape relative to the design. It is also an excellent tool for the Dies corrector. The Virtual Gauge is a novel solution that makes it simple and easy to know immediately if the profile is “OK” or “Not OK” using the quick, automated measurement method offered by the Go No-Go virtual gauge. The Virtual Gauge can be prepared easily from the opposite (reversed) computer-generated representation of the profile drawing.
Automatic Measurement of the Assembled Structure of Profiles – Romidot is the first company to offer to the Aluminum profile industry the ability to import a complete structural drawing of assembled profiles, to complete a thorough measurement of the sample-assembled profiles, and to check automatically for any deviation between the drawing and the sample profiles.
The application offers a method to make precise adjustments to the connection areas in assembled profiles, and allows the user to generate special deviation reports for these areas.
This application is also able to accommodate a variety of profiles, including structures built from multiple profiles. It also allows for precise measurement of zones with smooth connections or zones with hook connections.
Together, these new innovations by Romidot — robust machine design, reliable operation, real-time data sharing, the Virtual Gauge, and the automatic measurement of assembled structure of profiles — combine to create a unique solution poised to offer a new method of production for aluminum profile manufacturers.