The development of a weatherproof, welding-free, modular gate and fence system that can be easily assembled
Creators: name: Urban, Laszlo Artur
Publisher: name: Zenodo
Year: 2022

description: The development of a weatherproof, welding-free, modular gate and fence system that can be easily assembled

Project identification number: GINOP-2.1.2-8.1.4-16-2019-00802

 

The installation of fences and gate entrances with the currently used methods is lengthy, primarily as a result of the large-volume welding work, and in many cases requires continuous aftercare.

As a result of the research and development project, a weatherproof, modular gate and fence system that can be easily assembled without welding was developed. The elements of the system can be manufactured to exact dimensions at the production site, and can be easily assembled and precisely adjusted at the installation site with detachable connections. The novelty of the system is the simplicity of planning and assembly, as a result of which work processes that could only be carried out by specialists can be carried out individually, and the execution time is significantly shortened.

The developed system provides a modular solution that can be assembled extremely quickly and easily. The developed modular gate and fence system reduces the design and installation work, fewer components need to be transported, stored, handled and taken into account in the design. One of the main motivators of the development was that it saves customers time, which is an extremely bottleneck for both the corporate sector and the private sector, by using the products.

The design of the modular system also meets the needs of mass production, thus ensuring significant production efficiency. The modular product range is built entirely from typed and modular elements, all its elements - from the support structure to the hinge, fastening elements to the fence and gate elements - can be modularly connected, and from the side of the product manufacturer, it also results in typed production technology steps.

Within the framework of the project, a manufacturer-independent fixing system was developed for the installation of gate automation, which provides customers with the opportunity to use any manufacturer's product later on.

When choosing the raw material required for the modular system, we had to take into account the commercially available product suitable for outdoor use and with the required mechanical properties. During the basic material tests, the EN AW 6060 T66 F22 aluminum closed section was chosen. Closed sections and profiles made from this material are offered by many manufacturers, so their purchase is easy, and the purchase is not at the mercy of one manufacturer, in terms of prices, delivery times and quality.

            The 50x50 closed section defined above was also the basis for what kind of product the service provider should develop when developing the hinge system. In the case of commercially available parts related to the product, there were also aesthetic expectations, which the service provider solved with appropriate coating technology.

The pivotal issue of the welding-free technology is the creation of a sufficiently strong, size- and shape-retaining corner joint. For aesthetic reasons, the fixing of the corner could not be placed on the outer surface of the closed section, because it made the corners of the gate ugly, not to mention the fact that it hindered the slats to be installed inside. Based on the manufacturability and economy tests of the internal corner points, we arrived at the injection-molded corner element with a metal core. The metal core ensured a sufficient connection to the pivot pin bushing of the hinge developed by the service provider. We tested the serial production technology of welding stainless steel elements on a Cloos prototype welding robot, it was important to develop a precise, stretch-free welding technology for the elements so that the semi-finished product fits into the injection mold without error, ensuring the production of the exact corner point.

For the on-site assembly of the frames, we developed a drilling template and assembly technology, optimizing the time spent on on-site assembly. We managed to get to the technological level where our mechanics can assemble and install a normal-sized wicket door in approx. In 2 hours, the assembly and installation of a 3-3.5m double-leaf gate is carried out in about 3.5 hours. In order to be able to achieve these installation times, products have been developed for door slats. The fixing rail and the alignment plug help the installer to quickly and precisely install the laths inside the frame, for the stepless and quick adjustment of the lath distribution, and for the final fixing of the laths.

As a result of the research and development process, a massive, aesthetic gate system that can be assembled on site without welding was created. Completed with today's automation technologies, the product is the result of a successful development. It has the advantages of packaging, storage, and transportation, and the assembly does not require a welding specialist, it can be assembled with simple DIY machines with minimal technical knowledge.