Case study
Tents and shelters
THE PROJECT
One of the leading manufacturer of PVC-coated tents in Abu Dhabi reached out to us with the request to develop a continuous welding station to produce wall panels for their extra-large tents.
The goal was to speed up their semi-automatic production cycles while at the same time create very strong but aesthetically pleasing seams. Strength of the seams was extremely important due to the safety issues involved once the very heavy PVC panels are mounted in the tent structures.
THE PROCESS
We developed a multiple-roll sealer that feeds the fabric from 2 motorized unwinding stations with automatic edge correction and digital fabric tension control to manage jumbo rolls. A high-power welding head installed in a central position on the bridge joins the panels together while 2 lateral heads apply a single- or double-flag keder to either side of the fabric or fold the fabric into a pocket while automatically inserting a rope.
We installed a camera near every welding head to allow the (single) operator to continuously monitor the production process and the quality of the seams from a single control station. The machine grants easy access to all welding and cutting tools so that the operator can easily intervene should this be necessary.
Very flat, extremely strong seams. Increased production output.
We installed motorized pullers prior to and after the welding bridge that keep the fabric under exactly the right tension and make seams not only be strong, but flat and aesthetically pleasing
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