The Endeavor is extremely versatile, capable of routing and drilling virtually any common lock and hinge hardware, including specials like soss, paulmelle, and center pivot hinges, and even new lock designs with deep electrical connection pockets. Of course it will also process card locks, viewers, multi-points and pockets for flush bolts along the hinge edge – all with corners precisely squared using computer controlled chisels.
The Endeavor is a major departure from earlier Kval designs. It includes a pair of optimized stations designed to produce lock and hinge details in as little as 45 seconds door to door. More complex doors requiring card lock, viewer, and square hinge prep take about 80 seconds. All motions are CNC controlled for rapid and precise adjustment to the next door detail.
For machine logic, motion, door measurement, and the user interface Kval partnered with the Beckhoff group headquartered in Germany. The software is all new and was developed by an innovative programming team at Kval specifically for the Endeavor System using C-sharp and Structured Text. A single industrial computer system controls both stations; program and logic flow is seamless. Existing Kval customers’ machining files for earlier machines remain completely compatible.
The bases of both Endeavor stations are fabricated from ½” x 10 x 8 tubular steel. After welding, the bases are shipped to a specialist firm in Southern California to precisely mill rail bearing beds and to drill and tap mounting holes with a .001” tolerance. After painting, bearings and 35mm rails are mounted without shimming or fitting: they are just correct from the beginning. The build process continues with accurately machined components, precision oversize bearings and heavy duty routers designed to allow fast cutting speeds without flex or vibration. The combined shipping weight of the two stations is over 22,000 pounds.
The Endeavor is controlled with a single Beckhoff industrial computer for seamless operation of both detailing stations. Doors in each station can be unique. Barcode or RFID processing is highly recommended.
Brecoflex geared belt feed driven with Beckhoff servo motors and controllers. For precision machining, each door is digitally measured with six probes to confirm exact size and position.