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Profile connectors for aluminum construction profiles - Accessories
Precisely matched profile connectors are essential for the efficient construction of machine frames, guards and workstation systems. MISUMI’s webshop offers an extensive range of connecting elements that covers various mechanical requirements and profile geometries. What solutions are there and how can they be implemented? In this article, we provide a structured overview of some of the available variants and their engineering applications.
Profile Connectors
Profile connectors allow interlocking and friction-locking joints between aluminum profiles, thus significantly contributing to the stability of modular systems. At the same time, however, they also support the integration of attachments and easy disassembly when designs often have to be disassembled and reassembled. A flexible and scalable system is particularly advantageous for these cases.
There are different ways to join aluminum profiles. Profile connectors are principally distinguished into mounting brackets, which are mounted on the outside at the connection points, and blind connectors, which are located within the profile. T-nuts and screws are the most common method for joining aluminum profiles. Depending on the requirements, different systems such as quick connectors, block connectors or metal connection plates are available. These matched systems allow for quick and secure assembly and at the same time offer flexible uses.
Blind connectors
Blind connectors are elements that connect aluminum profiles from the inside without the need for externally visible connectors such as angle brackets or lugs. They provide a stable, interlocking joint and allow for a particularly clean, aesthetic appearance of the construction.
Interior angle bracket
Interior angle brackets also offer the advantage that they are not visible and provide a flat surface. These come in a flat shape, but also in a shape that is very similar to T-slot nuts. Interior angle brackets are usually inserted into the profile groove at the profile ends and are fastened with screws by clamping.
Installation example for the HABLBS5 interior angle bracket
Most interior angle brackets are inserted into the grooves of the aluminum profile and then secured. Some of the interior angle brackets, such as the HABLBS5 interior angle bracket (for series 5), can also be easily mounted afterwards. To do this, one simply inserts the interior angle bracket into the correct position (Fig. 1), inserts the corresponding T-slot nut with fastening pin (Fig. 2), and tightens the fastening pin with a suited tool (Fig. 3).
Corner connectors
Another way to join aluminum construction profiles is to use corner connectors. These are available in different versions. They are placed onto the respective profile end and fastened. Note that the profile length is reduced by the size of the corner connectors. Robust metal corner connectors are particularly in demand, as they provide increased load bearing capacity and thermal resistance.
Depending on the model, corner connectors can be used to join a varying numbers of aluminum profiles. The most commonly used variants are two-sided and three-sided corner connectors. These come in various forms and versions, some of which we will introduce to you here.
Some corner connectors also act as a cover at the same time. This type of corner connector is suited for environments with high dust and dirt loads.
Block connectors
Similar to the corner connectors, there are also block connectors that can be attached to the ends of the aluminum profiles. These also connect an aluminum profile to another profile at a 90° angle. The block design supports modular construction, offers a high-quality design, and simultaneously protects the profile ends.
Mounting base plates
Mounting base plates, also called plate connectors, can also be used for retrofit assemblies.
In the application example shown here, the profile to be mounted is first screwed to the base plate using the 4 inner mounting holes. The mounting base plate can then be securely mounted on the aluminum frame or profile using T-slot nuts inserted in the grooves at the outer fastening points. Mounting with T-slot nuts also offers the additional advantage of being able to move the profile laterally at a later point, if necessary.
Easy connector
Easy connectors for construction profiles are a very simple and reliable way to connect profiles at right angles. In addition, they offer the possibility of being used as a plate holder. The Easy profile connector is simply inserted into the groove anywhere on the aluminum profile. By tightening the screw, the Easy connector is securely clamped in the groove profile using a clamping piece.
A threaded hole is provided on the side of the Easy connector to mount cover plates for the enclosure. These can thus also be easily installed later. Such aluminum profile quick connectors reduce assembly time and allow modular extensions without disassembling existing structures. They are also ideal for retrofits in guards and workstation systems.
Angle connectors / mounting brackets
A mounting bracket / angle connector should be used if high loads are expected or high stiffness is required. These are configurable in different variants and sizes. Angle brackets with stiffening rib are suited for very high loads. These give the aluminum frame construction higher strength and rigidity. In addition, there are also angle connectors with a tongue as a position holder that engages into the groove and ensures the correct position of the T-slot nuts. No matter which connection is chosen, they remain releasable and offer very high modularity. Angle connectors with stiffening rib are also optionally available with a lateral threaded hole. These offer the additional option of enabling panels or shrouds for an enclosure or partitioning of different applications in industrial machinery.
But angled connectors also permit securely connecting construction profiles that run transverse to the groove. They enable a stable and reliable 90° joint.
There are different versions, depending on the design of the profiles to be connected and their profile cross-section:
Connection plates
Another variant, which can also be used additionally, is connection plates, which often connect or additionally stiffen the construction at the upper corners. The connection plates can be used not only at the upper corners, but also on other parts of the frame construction. They are also often used for additional stiffening when building laboratory equipment, such as instrument carts. They are preferably used where additional stabilization is required, e.g on long booms or moving units. They are also available as custom-sized connection plates to meet specific requirements.
Joint Connector / Tension Lever
Joint connectors with or without tension lever. are Very special profile connectors. These allow for adjustable aluminum profile constructions. Joint connectors with tension lever can be easily and quickly loosened and re-tensioned. This is advantageous if a frequent angular adjustment is required. Joint connectors without tension lever are designed for fixed and permanent angle adjustments. These are often used to insert a short aluminum profile as a stiffening element in the corners of the frame construction. These are also frequently used to create a dome-shaped upper enclosure of a machine, for example. A lateral assembly with joint connectors also increases design leeway for construction and frame construction.
Track rollers and drum rollers
Track rollers and drum rollers can be easily attached to aluminum profiles. They help to transport workpieces more easily. Entire conveyor belts can be realized using them.
It is also possible to use a conveyor roller shaft holder to implement conveyor systems with transport rollers.
Glide elements
Glide elements are used to slide aluminum extrusion profiles together in a low-friction manner. They enable smooth and precise movements, e.g. with sliding doors. They also protect the profile from wear and tear.
Plate holder / disc holder
Plate holders or disc holders are used to secure glass or plastic discs to aluminum profiles. They ensure stable, stress-free positioning of the plates. At the same time, they enable easy and flexible replacement of the clamped discs.
Equipment caster holder
Equipment caster holders are used to secure casters to aluminum profile structures. They provide a stable, resilient joint between the profile and the caster. This allows flexible and smooth movements of machines or frames.
In addition to different forms of fastening, there are also various versions with plastic, rubber, or polyurethane treads for appliance castors. Each of these versions has its advantages and disadvantages, which must be taken into account depending on the intended application.
In addition to appliance castors, feet can also be connected to aluminum profiles. For this purpose, a base plate is fastened to the profile end, to which the foot is fastened simultaneously.
Using corner connectors for aluminum profiles correctly
It is important to select compatible components: Aluminum profile connectors, T-slot nuts and profile sizes must fit together. This ensures that mechanical load bearing capacity and also dimensional stability are maintained.
Before connecting, ensure that the profile connectors are clean and free of burrs. Faulty machining of the connectors or improper profile sizes can lead to tolerance deviations that affect the overall stability of the design. Therefore, it is important to verify that all parts are deburred and trial-fitted before assembly. Careful design pays off with longevity and operational safety. Particularly in load-bearing designs, the use of robust aluminum profile corner connectors is recommended, as they enable stable and precise angular alignment.
