We have been building fully- and semi-automated assembly lines and test bays for over 10 years now, and also assume overall responsibility for implementing the turn-key system. Customers benefit from direct communication channels and intensive, comprehensive supervision by our project managers.
Among other things, the scope of performance includes design of the overall system, MTM analysis, layout, process design, part tracking (RFID, data carrier, etc.), construction, software, rework solutions, calibration and MSA as well as service all over the world.
Joining, pressing, screwing, welding (including electrical contacts), ultrasonic welding, bonding (including surface pre-treatment), filling, crimping, riveting and clinching are all processes which have been implemented already. Conventional or robotic solutions are provided for assembly processes according to the requirements. The consideration of cleanliness and ESD criteria is a key prerequisite for many systems in order to achieve the required level of quality.
As a rule, the solutions are fully set up at Klotz and tested extensively with regard to all quality and performance attributes. Customer sample production runs and testing functions can be performed in an ESD-compliant production environment even before relocating the system.
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.
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 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.
This assembly line serves to manually assemble and test power steering gears for commercial vehicles.
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.
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.
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.
When designing this system, we could fall back on 20 years of experience in the field of ring fitting, particularly for highly sensitive product such as enamel.
This knowledge, an awareness of the changes in the market structure (e.g. small runs, high quality, optimum delivery readiness of the operator) were the aims of the new development.
With this product we have developed an automation module that is proving its worth in production. The entire facility has been modified in a manner that points the way ahead for the future.
The main factor considered was simple operation of the machine and a high degree of automation of the operating process. This however is not sufficient on its own to comply with the parameters set by the customer.
For this reason, the facility was designed so that up to six pot and lid sizes – i.e. diameters – can be produced, with five options available
The machine can be operated from directly in front of the appropriate station in setup mode. The necessary control consoles are provided at the workplaces. When the safety grille is closed the consoles become inoperative.
As previously mentioned, the feed unit is provided with an adjusted half-dish that takes the part with its manually fitted rings from the conveyor belt and supplies it to the rotary table. The alternatives assume that the tool automatically adjusts to the sizes.
The enamelled part (pot or lid) arrives from the furnace chain, is removed manually, and checked.
The ring is then placed manually onto the part. The parts are placed in this condition onto the conveyor belt, which is of the backup type so that certain quantity can be positioned.
The separation of the transfer unit is already fully automatic. For rolling up or pressing on the rings, the parts are introduced by a pulling plate. This pulling plate has three no-load stations which can be used if required for knob fitting.
The fitted part is removed by a gripper that deposits the workpiece on a conveyor belt. There is an optional possibility of placing the parts in a carton.
When the safety grille is closed only automatic operation is possible.
After Emergency Off, each station can be moved to the starting position at the push of a button using the control panel on the switch-gear cabinet.
Cycle time: 6 to 7.5 sec
Width: 3.7 m
Length: 5.0 m
Height: 2.2 m
Weight: 2800 kg
Pneumatic connection: 6 bars, 1/2″
Connection load: 380 V, 25 A
Control voltage: 24 V
Min. diameter: 90 mm
Min. diameter: 300 mm
(other dimensions on request)
Control: Siemens S5-115U electric/electronic freely programmable and pneumatic-hydraulic
Electrical sequence: Single functions
Semi-automatic (automatic run of a station)