aluPilot: Streamlining Aluminium Window Production
Time is a critical factor in manufacturing and installing windows, and Winkhaus UK’s efficient concealed fitting system, aluPilot, is designed to optimise the production process.
Using aluPilot, aluminium fabricators can reduce production time by up to 10 minutes per window compared to traditional aluminium Euro Groove systems. Faster and easier installation can reduce the cost price of an aluminium window, saving time, money and increasing productivity.
This time-saving result has been confirmed through extensive testing with manufacturers during the development and roll-out of aluPilot to European and UK systems houses. When multiplied across weekly production, these time savings really start to add up.
aluPilot can be used across a range of modular applications including tilt turn, turn tilt, tilt only, turn only, and includes a range of restrictors and turn limiters. In addition to efficiency gains, aluPilot supports impressive weight capabilities, accommodating sash weights up to 300kg, making it versatile and adaptable to diverse applications.
Manufacturing concept
The drive rod concept of aluPilot simplifies and streamlines the window manufacturing process by eliminating several traditional steps:
• No cutting or punching of connecting rods
• No punching of profile grooves
• No waste from offcuts of connecting rods
• No Screws
With aluPilot, components are clicked into place, making the process more efficient and reducing cutting waste.
Installation concept
The installation concept involves connecting rods which are installed externally using a bayonet locking system for secure and efficient high-power transmission. The sash hinge is fixed seamlessly with a CLICK mechanism, eliminating the need for machining the sash profile and screwing the fitting system into place. Height adjustment is positioned at an accessible angle to facilitate easy adjustments, and installing the sash both at the bottom and top is tool-free and straightforward, enhancing accessibility and ease of installation.
Tool concept
aluPilot features a complete range of mounting accessories for easy installation:
Drive Mounting Tool: Secures the drive in the profile until connecting rods are mounted.
Positioning Aid: Determines keep positions accurately during installation of standard and PAS24 specification fittings.
Sash Edge Protectors: Protects sash corners during installation with concealed fittings.
Drilling Jig: Predrills PAS24 screw positions using a jig for pre-assembled keeps.
Jig for Security Locking Modules: Positions security locking modules on turn windows at the drive-side sash corner, suitable for both left and right-handed operations.
Smart packaging
'Smart packaging' ensures complete component protection and organisation in one box, minimising the risk of missing parts and simplifying assembly with pre-assembled components, and no loose parts or screws. The packaging is well-organised for efficient part retrieval, saving time during assembly. It reduces hardware by up to 25% (standard) or 70% (burglar-resistant), streamlines installation steps, and allows easy fine-tuning of keeps without damaging profiles.
Collaborative Development and Support
The aluPilot system is exclusively sold directly to systems houses, ensuring that the product range is customised and tailored specifically for their needs. This approach allows our customers to receive a bespoke range of aluPilot products that align perfectly with their particular profiles and specifications.
When integrating the aluPilot system, the components undergo rigorous testing in conjunction with the profiles provided by the systems house. This testing phase provides seamless compatibility and functionality, ensuring that aluPilot becomes an integral part of the profile design. By testing the "click in" system components alongside the profiles from the systems house, any necessary adjustments or fine-tuning can be made at Winkhaus to optimise performance and reliability, meeting the precise requirements of the system. This collaborative testing process not only enhances the integration process but also ensures that the final product meets high standards of quality and performance.
With over 100 years of combined industry expertise in product development, manufacturing, and testing, the Winkhaus technical and laboratory teams offer proven solutions to ensure the success of its partners’ future innovations. Our added value services include consultation, CAD design, 3D prototyping, product assessment, product development days, and UKAS laboratory accreditation.
Alastair Wheeler, Winkhaus UK’s Aluminium Systems Manager, stated: “At Winkhaus, we pride ourselves on being a collaborative partner, working closely with system houses to meet their specific needs. Through mutual development, testing, and certification, we ensure that each system house can enjoy the benefits of a bespoke window solution that saves precious production time.”
Among the tests offered are:
• PAS24: Enhanced Security Performance
• BS6375 (part 1, 2, and 3): Performance of Doors and Windows
• BS EN1634-3: Smoke Control Test
• TS007: Enhanced Security Performance
For further information on Winkhaus Laboratories' services or to discuss testing requirements, interested parties are encouraged to contact the team via email at test.lab@winkhaus.co.uk.
To learn more about the features and benefits of aluPilot, visit our website here, or contact marketing@winkhaus.co.uk.