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C3    Germany ZELTWANGER Automation GmbH
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We produce machines and plants, ready-to-install machine parts, components and stations in production lines.

ZELTWANGER manufactures as part of a continuously evolving integral production chain, controls and monitors all corporate divisions and raises quality and production standards. The tightly-knit development cooperation we undertake with our customers in the fields of design, production and assembly has helped to optimize our development performance and efficiency for many years, and helps to consolidate good long-term customer relations.
 
Product Line Up
ZELTWANGER Automation
Based on the principle "modular – individual – flexible" Zeltwanger Automation GmbH provides assembly and testing systems that are used in medical technology, automobile industry, and in general industrial applications. In addition to fully automated workpiece carriers and robotic assembly systems, we focus on manually linked "one-piece-flow" line concepts and ergonomic single user systems.

In the medical and bio-tech areas, we create systems compliant with the European and American standards and the guidelines of GMP (“Good Manufacturing Practice").
 
Seal testing systems
 
Seal testing systems with moving carrier plate
Seal testing systems with sliding carriage are used primarily for castings from gear box and engine, for cylinder heads, or large plastic components.

The benefit of the testing systems with sliding carriage is its modular concept and the ergonomic shape and feed height.
It also makes it possible to use various testing methods, such as overpressure, underpressure, differential pressure, and mass flow. The fact that it is easy to reconfigure for the different workpieces increases its flexibility and the automated feeding and unloading of components simplifies the process.
Seal testing systems "Lean"
The seal testing system "Lean" is designed to be an individual testing station for manual and automatic loading. It can be integrated into one-piece-flow lines and is suitable for smaller and medium sized plastic components, aluminum, and cast steel parts.

A big plus is its modular and space-saving design and its ergonomic shape.
It can be used for air testing methods or helium chamber leakage detection.

Another advantage is the great flexibility of the cell concept: various cell sizes, possibility of integrating into several processes, and a highly secure investment.
Seal testing methods with test gas
With the newly developed He-chamber leak test it is now possible for the first time to detect leakages of up to approx. 1*10^-4 mbar l / s under environmental conditions.
Compared to traditional He-methods, this procedure has the advantage that no energy- and maintenance- intensive vacuum pumps need to be used.

We offer mass spectrometry systems for the detection of leakages of < 1*10^-4 mbar l / s.
 
Assembly systems
 
One-piece-flow systems
One-piece-flow increases flexibility
One-piece-flow manufacturing is a production concept that helps prevent waste and is able to handle a greater number of variations for batch sizes of one. As our slogan "modular – individual – flexible" suggests, Zeltwanger does this by providing its customers with modular construction kits in the form of well thought-out process stations.

One-piece-flow manufacturing is logically based on line production. In contrast to conventional assembly lines, the employees do not stay in the same location all the time but accompany the workpiece the entire way from one assembly system to the next. By following through all assembly steps, workers can establish a better relationship with the product.
Chain systems
Chain systems are particularly useful for assembly jobs with a large number of individual processes with a high degree of automation.
We offer a number of standardized process modules depending on the workpiece size of 220, 440, and 660 mm grids.
In addition to traditional belt-based transfer systems, we also offer rapid feed systems for cycle-time-optimized workpiece carrier changes.
Testing systems
In addition to testing systems for seal testing we produce function testing systems. This also includes hydraulic nominal line testing for pumps, and electrical testing of circuits.
 
Rotary indexing table systems
Revolving transfer table systems are suitable for assembly jobs that usually require up to eight individual assembly steps. On many cases a worker loads and unloads the workpiece. Another advantage of Rotary indexing table systems is the quick transfer of workpieces from station to station. Rotary indexing table systems distinguish themselves through a better price/performance ratio compared to longitudinal chain systems.
Palletting systems
The benefits of our palletting assembly are obvious. Its slender construction, its modular concept, and the arbitrary expandability of the vertical and horizontal stacking units provide a great degree of flexibility.
The ergonomic blister feed height allows for reliable work that is additionally supported by the freely programmable stacking path for different blisters.
  
 
Polishing systems
 
Kreativ in die Zukunft gedacht mit variablen Robotersystemen

ZELTWANGER hat sich bereits seit den Anfängen des Geschäftsbereichs Automatisierungstechnik mit dem Thema Polieren von orthopädischen Komponenten für die Medizintechnik beschäftigt. Meist sollten manuelle Polieraufgaben automatisiert werden. Dabei hat sich die ZELTWANGER Automation GmbH umfangreiche Kompetenzen bei keramischen Werkstoffen angeeignet, wie sie in der Medizintechnik zum Einsatz kommen.

Für das Polieren von komplexen Freiformflächen haben wir ein variables Robotersystem entwickelt, welches beispielsweise bei orthopädischen Komponenten aus Metall oder Keramik Verwendung findet. Zur Voreinstellung der Prozessparameter können mit Hilfe unserer Polieranlagen alle Arten von Oberflächen zum Test poliert werden.

Neben dem Polieren sind wir auch auf roboterbasierte Entgrat- und Bearbeitungsprozesse spezialisiert. Um individuell auf kundenspezifische Anforderungen eingehen zu können, führen wir in unseren Anlagen Vorversuche mit einzelnen Werkstücken durch. Für optimierte Ergebnisse bei Entgratvorgängen verwenden wir auf die Anforderungen unserer Kunden abgestimmte Geräte.
 
Plug assembly systems
 
 
We offer turn-key plug assembly systems for the manufacture of plugs and housings with integrated contact surfaces. These systems contain the following processes: pin placement, injection moulding, testing, and palleting. Our modular, flexibly expandable pin placement system is suitable for placing punch-bend pieces and pins that are fed by belts and formed or sheared to length by integrated punches. The pieces are fed either directly into a workpiece carrier that is fed into the injection moulder as a "hot insert" or into a workpiece carrier that carries the pre-placed parts to the injection moulder. For competitive reasons the images do not correspond to our latest state of development. Please contact us for questions in this regard.
         

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