Task:
Contactless crankshaft measurement in a single setting using a triangulation laser

Solution:
Until recently, crankshaft measuring used to be a time consuming process due to the complexity of the measurement features (caused for example by the excentric rotation of the pin bearings with a particularly large amplitude). A further innovation step – the synchronization of the XY axis combination with the rotary motion of the pin bearings - now makes it possible to measure the main bearings as well as the pin bearings in one single setting.

Advantage of the system:
The short cycle time of the total measurement now enables our customers to conduct a 100 percent quality control and classification of the crankshaft during the current production. Moreover, the new procedure allows the traceability of the measured values in order to automatically adjust the processing machines. All in all, this results in cost savings while improving the quality at the same time.

Task:
The gear is an extremely complicated component that is affixed to the motor block within the framework of the aggregate-assembly process. Only when motor and gear are joined as exactly as possible can the optimum functional reliablility of the gear be guaranteed.

Solution:
All in all six cameras capture the position of the driving plate and gear shaft in order to join the gear exactly according to the two and three-dimensional measured values. Robots link motor and gear via a screw in accordance with the torque - a novelty in the Automotivee industry.

Advantage of the system:
Besides its high degree of automation the system also offers a more humane and safer work place. The precision of automatic assembly results in higher quality as well as a longer life span and lower noise levels in the vehicle later.

Task:
Automatic assembly of electric locking brakes on a transfer system

Solution:
The individual parts to be assembled are manually positioned on a work-piece carrier. Besides various automatic screwing processes, e.g., a one-component sealing liquid is applied by a robot and checked for 100 % completeness. All materials are scanned in by means of a barcode which makes it possible to trace the product all the way.

Advantage of the system:
The data handling results in superior product quality and product documentation. By means of flexible automatic modules different products can be run simultaneously in a mix in order to be able to manufacture mini-series economically with the quality of mass-production series.

Task:
Automatic assembly and adjustment of a sliding roof.

Solution:
Autarchic robot system integrated in the conveying flow.

Advantage of the system:
Weight reduction due to the use of a carbon gripper
Highest availability.

Task:
Feeding of work-piece carriers to manual work station via monorail system

solution:
The robot takes out a work-piece carrier from the monorail which runs on one level above the manual work stations and positions it optimally for the worker through an opening in the ceiling. After processing the part (e.g. removal of doors from the varnished body) the worker releases the robot which then transports the work-piece carrier back to the monorail.

Advantage of the system:
By using a robot changes to the component or the procedure are implemented faster.

Task:
Exchange of varnished crossheads and assembly crossheads by means of a turnstile

Solution:
The crossheads for enamelling and assembly are designed in a different way. The automated change of these transport bottom parts is done outside of the actual manufacturing line. The vehicle is removed from the line and equipped with the new crosshead in two steps on a cross-shaped device rotating around the vertical axis.

Advantage of the system:
Whereas before a mechanical conversion was necessary when implementing a new type of crosshead, the new process is now implemented: vehicle data as well as component data can be modified at will. Significant saving of space in comparison to conventional systems.

Task:
Automatic feeding, cleaning and packing of mobile phone displays

Solution:
Combination of transfer and robot systems as well as integration of high-resolution camera systems and newly developed cleaning and packing procedures.

Advantage of the system:
High degree of automation; 100% quality control; Interlinking of different process steps

Task:
Automatic assembly of office chairs.

Solution:
Modular design of robot cells and transfer technology using intelligent sensor technology..

Advantage of the system:
High availability; Flexible identification of various chair components with minimum pre-production time.

Task:
Automation of screening systems, storing, packaging and provision of testing substances

Solution:
Integration of transfer and robot technology, barcode laser, weighing technique with intelligent servomotor technique and gripper systems

Advantage of the system:
100% product tracing

Task:
Automation system for screwing down hub bearings

Solution:
IBG Robot cell with camera and screwing system

Advantage of the system:
The time-consuming manual screw-fitting process is significantly shortened due to an intelligent robot control system. By monitoring torque and torque angle constant screw-fitting values are achieved.

MAGAS: The first fully-automated
operation microscope.

As problems become more and more complex, more innovative measuring systems are required and digital image processing becomes ever more significant.

Application areas of image processing include:

• 3D measuring technique
  The touch-free capturing and/or measuring of geometries of space with optical methods
• Quality assurance
  Monitoring the exact adherence to geometric dimensions in the production process as well as checks for completeness of the assembly process
  The data supplied are evaluated in the control device of the system which enables us to realise even the most complex tasks in an economical way.

Our pressing-in systems make possible a force-displacement monitored joining of components.

This is realised pneumatically, hydraulically or via servomotor with PC control system.

The photo show an example of a pressing-in system developed by us which are tailor-made solutions in almost any sphere.

Flexible gluing and bonding systems make possible the production and assembly of very different components.

Rail-controlled robots apply gluing and sealing runs on the components and join them afterwards.

During the application of the sealing agent the completeness of the run is verified simultaneously by way of laser scanning in order to guarantee the quality of the final product

Storing systems guarantee that components are available in a fixed sequence.

With the help of robots components can be taken out from the storing systems in the correct sequence without any loss of time for subsequent use.

The use of different simulation tools makes possible the visualisation of the worked-out system processes. These simulations allow the immediate identification and optimisation of critical areas.

Due to the use of COSIMIR and RobCAD we are able to simulate complete work cells with all integrated components such as robots, stored programmable control systems, feeding and transport devices as well as sensors.

State-of-the-art screwing technologies make possible a process-safe and monitored performance of screw-fitting process in the most confined of spaces.

For self-monitoring these systems can also be designed redundant.

Flexible software makes it possible to screw down the most different materials.

We develop multi-purpose transfer and feeding solutions in standard design or in accordance with the task presented to us.

Like in all our speciality areas our product range here is always developed further with the aspect of innovation in mind.

The complexity of the tasks to be solved again and again requires the interaction of several intelligent systems.

Based on our long-standing experience in the spheres of PC, robot and PLC programming we are able to cover all areas of software development.

We use state-of-the-art technologies which our specialists are constantly further educated in.

Building switch cabinets in our own plants enables us to ensure the high quality standards we impose on ourselves in all the manufacturing areas of an automation project.

Here we fulfil all valid international standards and guidelines and implement them also with our customer-specific release.

All functions are tested for perfect functional reliability in our plant prior to any delivery in order to guarantee a smooth putting-into-operation.

We make possible the preparation of state-of-the-art circuit diagrams and layout plans by using CAD systems such as WSCAD and EPlan.