• Offer Profile
  • Klotz specializes in the design and manufacturing of assembly lines and test benches, in particular systems for the production and testing of vehicle steering systems and their components. The development of modern technical software for the automation of machinery and equipment is in addition to the traditional engineering the logical continuation of the corporate strategy: cutting-edge innovation.

    Klotz provides hands-on technology. Where else engineers and computer scientists can see immediately the success of their work? Whether technology in the machine or algorithm for control: The staff at Klotz reinvent mechanical engineering. Industry 4.0 and the Internet of Things can be experienced every day in exciting projects for international clients at Klotz.

Product Portfolio
  • Measurement and Testing Equipment

      • End-of-Line test station for electric power steering systems (EPS/EPAS)

      • 100 % testing of EPAS systems, integrated in the assembly line. In addition to the function tests, the test bench also performs an acoustic test on every steering gear.

        The new generation of Klotz steering gear test benches are based on many years of practical experience as well as the results of research and development studies. Computer-controlled function tests can be performed on mechanical and electromechanical rack-and-pinion steering gears. The scope of delivery also includes implementation of the external bus simulation (CAN/Flexray).

        The test bay integrated in final assembly generally consists of several autonomous test benches, each equipped with a hydraulic unit for the clamping functions.

        Every test bench primarily consists of:
        • Base with base frame and pinion drive frame
        • Electro-mechanical or hydraulic load units on the left and right
        • Docking unit for vehicle points on the left and right
        • Drive unit input shaft with centring gripper as well as torque and angle sensors
        • Units for docking the power and bus connection to the steering column
        • Safety systems
        • Control cabinet, PC and control panel
        • Flexible and expandable test bench software, with all quality data saved to a central location
      • Test bench for pedal assemblies and brake boosters

      • Testing of pedal assemblies and the individual pedals, brake boosters, wheel brakes and clutch control systems in combination with various loads such as volume transducer brake systems, wheel brakes, clutch slave cylinder and transmission case test devices with clutch and clutch slave cylinder.

        Specifications: Testing under extreme temperature conditions (possible in the temperature-controlled chamber)

         
      • Durability Test Bench for Rack and Pinion Steering Gears

      • This test bench is used to carry out durability tests of manual and power-assisted rack and pinion steering gears. Static and dynamic tests up to 30 Hz tie rod load run computer-controlled. The drive unit can be adjusted in 4 axes, the load input unit in 2 axes. By TCP/IP interface, the status of the current tests can be queried by any computer concerned.
      • Laser Measuring Station

      • Description of laser measuring unit
        The basis is a laser scanner centered on a helium/neon tube emitting a parallel-aligned pencil-thin laser beam.

        This permits rapid and high-precision measurements to be made on the workpiece without the need for any adjustment.

        The diameter and the edges are measured, and bevel, curve and roundness measurements are possible as an option.

        Specification of standard version
        Measuring ranges:
        Diameter: 4 to 120 mm
        Length: 5 to 700 mm

        Measuring time:
        Diameter: > 1 sec.
        Length: > 10 secs.

        Measuring accuracy:
        Diameter: 0.005 mm
        Length: 0.05 mm
      • Test Bench for Single and Continuous Tests of Axial Joints

      • The axial joint test bench subjects different axial joints to severe single and continuous load tests. Duty cycles, angular movements, temperature and air humidity can be preselected freely. Failure criterion is the axial play that develops or the breakage of the axial joint.

        Technical brief description:
        The test bench allows the simultaneous test of a maximum of 4 axial joints.
        The axial load for each joint and the angular movement for all joints together are applied by servo-type hydraulic cylinders. The control of axial load and angular movement is optionally linear or sinusoidal.
        Each test location has a separate support and individual test adapters. This allows simultaneous test of different axial joints.
        The axial play is determined by measuring the movement between housing and joint bar at a given load on the axial joint. If a joint is defective, the corresponding cylinder is cut off. Time of failure, number of cycles and development of axial play are recorded.
      • Power Steering Test Bench for 100 % Testing in Assembly Line

      • The test bench carries out fully automatic functional testing of hydraulic rack and pinion steering gears. Due to the automatic identification of the steering gear types, the test bench adapts virtually automatically to different steering models. So only few, or ideally no, manual operations are required when model change is carried out.

        The integrated tool magazine minimizes the non-productive times and the work to be performed by the operator during tool change or resetting. This increases productivity and efficiency significantly. Because of the short resetting times, even small batch sizes can be made economically.
      • End-of-Line Test Station for Commercial Vehicle Steering

      • Durability Test Bench for Axial Joints

      • Test Bench for Single and Continuous Tests of Axial Joints

        The axial joint test bench subjects different axial joints to severe single and continuous load tests. Duty cycles, angular movements, temperature and air humidity can be preselected freely. Failure criterion is the axial play that develops or the breakage of the axial joint.

        Technical brief description:
        • The test bench allows the simultaneous test of a maximum of 4 axial joints.
        • The axial load for each joint and the angular movement for all joints together are applied by servo-type hydraulic cylinders. The control of axial load and angular movement is optionally linear or sinusoidal.
        • Each test location has a separate support and individual test adapters. This allows simultaneous test of different axial joints.
        • The axial play is determined by measuring the movement between housing and joint bar at a given load on the axial joint. If a joint is defective, the corresponding cylinder is cut off. Time of failure, number of cycles and development of axial play are recorded.
      • Durability Test Bench for Rack and Pinion Steering Gears

      • This test bench is used to carry out durability tests of manual and power-assisted rack and pinion steering gears. Static and dynamic tests up to 30 Hz tie rod load run computer-controlled. The drive unit can be adjusted in 4 axes, the load input unit in 2 axes. By TCP/IP interface, the status of the current tests can be queried by any computer concerned.
      • Transmission Test Bench

      • The test bench serves to determine and test the control characteristic of automatic transmissions with hydraulic and electronic control.
        The tests are carried out on steplessly variable automatic transmissions as well as on automatic multi-step transmissions for front-wheel drive and rear-wheel drive and on special transmissions.
        Static and dynamic test operation
      • Radiation Measuring Unit for Barrels with Nuclear Waste

    • Assembly Equipment

    • From simple mounting devices to fully-automated assembly lines. And especially where special measuring, testing or monitoring requirements are closely linked with the assembly.
        • Final assembly and testing of electric power steering drives

        • Assembly line for joining and screwing the motor and ECU, welding of contacts, surface pre-treatment, applying protective covers, flashing the ECU and leak tightness testing as well as function testing.

          Specifications: High technical availability, cleanliness and ESD requirements.
        • Fully Automatic Screwing, Measuring and Setting Station for Steering Gear Assembly

        • The steering assembly machines are used for type-dependent bolting of housing covers, measurement of axial play and presetting of the frictional torque on commercial vehicle steering gears in the assembly line. Automatic identification of the steering gear types enables types to be changed without manual intervention.

          The facility is part of an assembly line for commercial vehicle steering gears and is intended for the type-specific screwing of housing covers, measurement of axial play and presetting of friction torque.

          Automatic identification of the steering gear types allows changes of types without manual operations.

          Workpiece feeding is by a belt conveyor which passes through the stations.
        • Fully Automatic Assembling Equipment for Steering Valves

        • The equipment recognizes fully automatically the position of steering valves in containers and fits these with controlled force on rack and pinion steering gears. In addition, grease is applied to the rack and the support bearing is supplied by the equipment. For handling the components, an industrial robot is used which is fitted with an imaging system and a force-moment sensor.

          The whole equipment is completely integrated into an existing assembly line and operates on a three-shift basis.

          The result is a constantly high quality at a cycle rate of 23 seconds and reduction of the reject rate to a minimum.
        • Assembly Line for Commercial Vehicle Steering Gears

        • This assembly line serves to manually assemble and test power steering gears for commercial vehicles.
        • Semi-Automatic Assembly Press for Seals and Bearings in the Steering Gear Housing

        • The assembly press serves to press into the steering gear housing of commercial vehicles radial shaft seal, roller bearing and wiper and apply grease to these.

          Placement and position of the components to be pressed in are monitored with sensors.

          All fitting and pressing operations are load/travel-controlled to satisfy and demonstrate quality standards. The fitting processes are indicated graphically.

          The assembly press can be converted to different types of housings, bearings, and sealing rings. To exclude mix-up, all tools and holding fixtures are coded.
        • Fully Automatic Ring Assembly Machine

        • Task:
          Fitting of ornamental and facing rings must be fully automatic since the systems developed so far have not optimally met the demands placed on our customers by the market.
          The call for greater flexibility and increased productivity required from us a new development concept. In addition to an inexpensive solution, the necessity for high availability and loading capacity were the main requirements.
      • Production and Manufacturing Equipment

      • The production and manufacturing technology was the beginning of everything. And it represents one of the company’s main product lines still today, such as the globally legendary fully automatic production facility for ornamental and facing rings.
          • Production facility for ornamental and facing rings

          • The KLOTZ Ornamental-Ring Automatic
            Rapid, dimensionally accurate and, above all, inexpensive, fully automatic volume production of ornamental, facing and housing rings for a very wide range of applications

            Quality based on precision
            Our machine makes — fully automatically — dimensionally absolutely accurate rings of constantly high quality. Between the minimum diameter and the maximum diameter (see technical data), all ring sizes can be manufactured with different profiles. Switching to another diameter is carried out by simple exchange of the holders.
            The ornamental-ring automatic provides in particular a solution to the problem that has existed to date, i.e. overlapping the ring ends, which decisively influences the quality of the rings. The machine does not only provide accurate overlapping of the ring ends, but also maintains the ring to size during welding (calibration of the diameter). This ensures a neat and uniform weld.

            The result:
            Precision weld, rings true to size, highest quality
            Operation and control: simple and comfortable

            A well-arranged and self-explaining control console makes the use of the machine simple and comfortable. As the whole process is fully automatic and the machine controls itself, a single person can operate several machines at a time. The machine works on the basis of a programmable controller and has remote maintenance capability.
          • Semi-Automatic Production Facility for Ornamental and Facing Rings

          • Flexible production facility for rings

            Rapid, dimensionally accurate and, above all, inexpensive, semi-automatic volume production of ornamental, facing and housing rings for a very wide range of applications.
            Brief description of working process
            • The strip as unwound from a fully automatic reel is pulled through a strip deburring device. In an electronically controlled length cutting equipment, the strip is measured accurately and cut to length with no burr developing. The piece of strip cut to length is placed in a container or a discharge chute.
            • The operator takes the strip cut to length and puts it in the welding machine. There it is clamped and welded into a ring.
            • The welded part is placed by the operator in the pneumatically/hydraulically-controlled profiling machine. There the ring is shaped as desired.
            • Ring ejection is fully automatic and can be controlled such that the ring is placed directly in a container. An also available option is positioned putting down for a ring-fitting machine further down the line.
            • All three systems can be handled by one operator. For the production of higher quantities, an intermediate depositing area after welding can be provided. Then the profiling machine is operated by another person.
          • Fully Automatic Production Facility for Cake Tins (Springform Pans)

          • The fully automatic machine is intended for rapid and economic production of complete cake tins (without bottom) of constantly high quality.

            This facility solves above all the frequent problem of quality fluctuations and resulting production troubles. The surface finish of the final product meets maximum requirements. In addition, a substantial increase in productivity is achieved as a result of the very good cycle time of up to 4 seconds.

            Due to the short resetting times – only the tool set has to be changed — even small batches can be produced economically. The facility is designed for 3-shift operation and can be operated by one person.
        • Handling Equipment

            • Lift and Tilt Mechanism for Enamel Coated Baking Boxes

            • Mould Gripper for Interim Storage of Radioactive Waste

            • Task:
              For the disposal from nuclear power stations, it is necessary to seal the nuclear waste with glass and cast it in moulds. The handling of those moulds occurs in a manless system. This is aggravated by the fact that the temperature in the bottles is approx. 600 C.
              For the handling of such moulds a gripper is to be engineered.
            • Ultrasonic Test Bench with Handling Means for Volume Production

          • Services

          • Services:
            • Industry servicing, maintenance and system calibration
            • Control technology: planning and production of electrical equipment, control systems, regulation systems and switchgear
            • Drafting of wiring diagrams
            • PLC programming
              • Technical Software

              • In addition to special machinery technical software is one of our core competencies. With KinRig Klotz has created a flexible product for both, operators of equipment and equipment constructors. By means of KinRig automation tasks and testing tasks can be implemented quickly and standardized.

                Kinmatec
                In addition to special machinery technical software is one of our core competencies. With KinRig Klotz has created a flexible product for both, operators of equipment and equipment constructors. By means of KinRig automation tasks and testing tasks can be implemented quickly and standardized.