{"id":15345,"date":"2023-03-02T14:25:07","date_gmt":"2023-03-02T12:25:07","guid":{"rendered":"https:\/\/pivatic.com\/solutions\/hvac\/"},"modified":"2023-03-03T09:48:55","modified_gmt":"2023-03-03T07:48:55","slug":"hvac","status":"publish","type":"solutions","link":"https:\/\/pivatic.com\/de\/solutions\/hvac\/","title":{"rendered":"HVAC"},"content":{"rendered":"\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\tHeizungs-, L\u00fcftungs- und Klimaanlagen regeln die Temperatur, Feuchtigkeit und Reinheit der Luft in Wohn- und Gesch\u00e4ftsgeb\u00e4uden. Dazu geh\u00f6ren auch die Wassererw\u00e4rmungs- und -umlaufsysteme. Bleche werden aufgrund ihrer Korrosionsbest\u00e4ndigkeit, Langlebigkeit und Wiederholbarkeit im Prozess sowohl f\u00fcr Produkte im Au\u00dfen- als auch im Innenbereich verwendet. Der Sektor w\u00e4chst aufgrund der schnellen Urbanisierung, der Verbesserung des Lebensstandards und der Energiesparprogramme im Baugewerbe. Die Saisonabh\u00e4ngigkeit der HLK-Branche f\u00fchrt zu starken Nachfrageschwankungen im Jahresverlauf.\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t
\n\t\t\t
\n\t\t\t\t\t\t\t\t\t\t\t
\n\n\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\"Boiler,Room,\t\t\t<\/span>\n\t\t\t\n\t\t\t\t\t\t\t\tHeizung<\/span>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t\t\t\t\t\t\t\t\t
\n\n\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\"Industrial,Air,Duct,Ventilation,Equipment,,3d,Illustration\"\t\t\t<\/span>\n\t\t\t\n\t\t\t\t\t\t\t\tL\u00fcftung<\/span>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t\t\t\t\t\t\t\t\t
\n\n\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\"Air,Heat,Pumps,And,House,,3d,Illustration\"\t\t\t<\/span>\n\t\t\t\n\t\t\t\t\t\t\t\tKlimaanlage<\/span>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t
\n\t\t\t\t\t\t\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t\t\t\t
\n\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\"Boiler,Room,\t\t\t<\/span>\n\t\t\t\n\t\t\t\t\t\t\t\tHeizung<\/span>\n\t\t\t\t\t\t\t\t<\/i>\n\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t\t\t
\n\t\t\t\t\t\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t

Heating systems for air and water are used in both commercial and residential spaces. The total systems include different types of fans and conductors, but here we will focus on the terminal equipment of heating.<\/p>\n

Our strengths and studies are about electric radiators and water heaters, but other examples of heating systems utilizing sheet metal are for example water radiators, oil heaters, panel heaters, furnace blowers, heat pumps, underfloor heaters, and garage heaters.<\/p>\n

CHALLENGES AND REQUIREMENTS (ELECTRIC RADIATORS)<\/h3>\n

The mobile electric radiators and heaters are used as additional heating methods in buildings or areas where the fixed water, gas, or oil heating systems don\u2019t suffice. The largest market for electric radiators is in Scandinavia and Russia. As the ways of producing electricity are advancing, electric heating is becoming more and more environmental-friendly compared to other ways of heating, although it was considered a great evil in the past.<\/p>\n

Electric radiators are produced for both residential and commercial buildings like households, offices, leisure homes, and garages. Their demand is focused on the season of winter so the production efficiency and reliability at this time needs to be exquisite. These high-volume products of over 500 000 pieces per year from one manufacturer are produced in large series as assembly kits of the front plate and the back plate. The cycle time requirement for a single assembly kit is a demanding 40 seconds. Due to the seasonal nature of production, preparing for increasing demand requires that the new machines are installed and ready in time, as a delay in the schedule may lead to the project being carried over to the next year.<\/span><\/p>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

\n\t\t\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t<\/a>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t

Electric radiator assembly<\/p>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t

\n\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t<\/a>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t

Front plate and back plate<\/p>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t

Process and Material<\/h4>\n

The material used in the radiators is thin 0.5 \u2013 0.8 mm pre-painted mild steel without exception, so the process needs to be material-friendly without buffer storage. The punching and bending process should be in contact with the stage assembly, where the heating and electrical elements are installed on the back plate. Finally, the front and the back plates are clinched together. The product models are standardized with a few height variations and several widths. Size differences are due to the required heating power, assembly equipment, and appearance. Every manufacturer has its own range of radiator models. To have changes made for the radiator models is a very slow process due to electrical regulation approval projects, and manufacturers tend to use the same models for several years or even decades.<\/p>\n

Punching<\/h4>\n

The challenges in punching are the several holes and openings for different attachments, assembly, and air circulation holes. The holes required for the front plate and the back plate are different: the back plate has several attachment holes, large corner notches, and the perforated supply air grate. The front plate has louver holes for the entire width of the radiator, so for different radiator widths, the press tooling needs to be programmable. The louvers are also so close to the long side edges that they have to be produced after bending to avoid being flattened. The products can also have branding as an extrusion form which also requires some press tool technology.<\/p>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

\n\t\t\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t<\/a>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t

Front plate louvres<\/p>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t

\n\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t<\/a>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t

Back plate supply air grate<\/p>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t

Bending<\/h4>\n

The challenges in bending come from the visual shapes of the front plates: rounded edges and complicated corners require special tooling for the benders. The long sides of the front plate and the back plate also have different profiles, so the bending machines need to be suitably flexible. By only having upward bends though, there is a selection of manufacturing technologies to choose from.<\/p>\n

SOLUTION (ELECTRIC RADIATORS)<\/h3>\n

Pivatic offers fully automated production lines for manufacturing all of the required radiator sizes as assembly kits<\/a>. The production line can run unmanned for long periods of time and it is easy to use, as all parts in the product families are programmed beforehand in the startup process of the project. Pivatic\u2019s punching and bending line, the PivaSystem<\/a>, can be integrated into the subassembly line without the need for buffer storage.<\/p>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t<\/a>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t

For the punching process, we recommend coil manufacturing<\/a>, as the coil width can be chosen according to the radiator height. The radiator length is thus programmable and the process produces no excess slug. A flexible Thick Turret punching station<\/a> has a minimum number of 24 slots to equip thick turret tools or cluster tools. The cluster tooling can be used for perforating the back plate supply air grate. A separate press too<\/a>l is required for the louver forming, and it is added in the PivaBend process.<\/p>\n

To have the bending process up to speed with the punching, we recommend a bending line<\/a> with four bending units, one for each side of the part. After bending the long sides, the louvers are formed and the part is transported to the short side bending station. The upper hold-down tool of a short side bender is divided into sections so that it can be adjusted according to the width between the long side bends.<\/p>\n

CHALLENGES AND REQUIREMENTS (WATER HEATER)<\/h3>\n

Domestic and commercial water heaters and storage tanks have sheet metal as the outer shell, inner shell, and top and bottom cups. The cover and the shells are single mild steel or stainless-steel sheets that are bent to the perimeter, and the end parts are formed from discs to create sealed containers. The total yearly volume of water heaters is in the hundreds of thousands.<\/p>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

\n\t\t\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t<\/a>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t

Water heater assembly<\/p>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t

\n\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t<\/a>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t

Water heater inner shell<\/p>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t

The different parts have material requirements due to their resistance to heat; the inner shell and its end parts are in contact with hot water and require a duplex stainless-steel material to withstand corrosion. Mild pre-painted steel for the outer shell and end caps will suffice due to insulation in-between. The challenges for punching are the varying pipe insertion holes in the shells, automatic handling of the circular end discs, and the forming press technology required.<\/p>\n

The inner shell is welded complete to eliminate possible leakage even in the highest of water temperatures. The outer shell is attached to the inner shell by a seam with a plastic strip. The products are marked for traceability and to help with the assembly process.<\/p>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

\n\t\t\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t<\/a>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t

Outer shell and inner shell<\/p>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t

\n\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t<\/a>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t

Outer shell marking<\/p>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t

SOLUTION (WATER HEATER)<\/h3>\n

Pivatic offers different punching and forming solutions for the shells and the end parts, with the possibility of a fiber laser or mangle integration. For outer and inner shells, the coil punching solutions are recommended to have programmable length for the sheets to be cut to the shell diameter. The different heater heights can be manufactured from different widths of coils, up to 2000 mm \/ 78\u201d wide. A flexible Thick Turret punching station<\/a> can be equipped from 24 different punching tools upwards, and a press tool station<\/a> will be used for circular cuts of the discs and\/or forming the discs. A labeling, inkjet, or laser marking device can be added to meet the traceability requirements for the parts.<\/p>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

\n\t\t\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t<\/a>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t
\n\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\t\"\"\t\t\t\t\t\t\t\t<\/a>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t
\n\t\t\t
<\/div>\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t
\n\t\t\t
\n\t\t\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<\/div>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t\t\t\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t\t\t\t
\n\t\t\t\t\t\t\t\t\t\t\t\n\t\t\t\"Industrial,Air,Duct,Ventilation,Equipment,,3d,Illustration\"\t\t\t<\/span>\n\t\t\t\n\t\t\t\t\t\t\t\tL\u00fcftung<\/span>\n\t\t\t\t\t\t\t\t<\/i>\n\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t\t\t
\n\t\t\t\t\t\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t\t
\n\t\t\t
\n\t\t\t\t\t\t
\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t

Ventilation devices and channels take care of the distribution, filtering, and noise cancellation of fresh air and improve fire safety for factories, residential buildings, and commercial areas. The air handling devices in the technical areas, ventilation channels, and fire dampers within, as well as the end devices before room spaces, form the largest volume of sheet metal products in ventilation.<\/p>\n

Other products for the ventilation segment are for example airflow dampers, chilled beams, air handling units, sound attenuators, smoke extractors, and industrial ventilation fans.<\/p>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

\n\t\t\t\t
\n\t\t\t\t\t\t\t