Specialty Window Snake Tool Pulling Improvement

Project Summary

Renewal by Andersen custom-bends their unique composite material to create curved window frames; the bending process can cause kinks or defects that ruin the appearance. To prevent this, reusable plastic support tools are inserted into the hollow frame. Unfortunately, tool removal by hand after bending can be difficult for the employees, increasing cycle time and risk of injury.  The design team’s solution is to refine the support tool shape for easier removal with testing and design a ball screw-driven actuator that eliminates the need for manual tool removal. To evaluate the effectiveness of the tool reshapes, the design team developed a
fixture that allows for repeatable and consistent testing and results.

Design Goal

Improve the ergonomics and cycle time of Renewal’s custom window frame bending process.

Design Constraints

• Material of support tools shall be manufacturable into multiple different shapes
• Solution shall not result in any visual defects on window frames
• Support tools shall be able to bend to different radii, from 12” to 58”
• Support tools shall not melt at temperatures of 130 °C or less
• Solution shall meet a cycle time of 30 seconds or less
• Solution shall not exceed a unit cost of $15