In the assembly of vehicle components, there are numerous concepts in various degrees of automation. Many processes are still implemented manually today, and the step towards automation often represents a major hurdle for companies.

We want to provide our customers with full support during the changeover and accompany them on their way from manual assembly to automated manufacturing of their products.

Component design, assembly sequence and tolerance concepts - the basic prerequisites for functioning automation

The design of the component is the central aspect when it comes to a possible automation of the assembly processes. In order to guarantee the integrity of the components, gripping areas must be defined, for example. The component design should also be such that a sensible assembly sequence is ensured. If possible, cost-intensive components should be integrated as late as possible in order to minimise possible scrap costs in the event of a failure.

Another decisive point is the provision of the individual parts. If, for example, pins can be made available as bulk material and processed by the worker without any problems during manual assembly, it is not so easy to make them available as bulk material during automated assembly. Separation and feeding via vibratory bowls could result in damage to the pins - delivery in trays and processing via so-called tray stacking systems or feeding via anyfeeder systems would be a conceivable solution here. We bring our experience to bear as early as the concept creation stage and give our customers recommendations in the area of parts logistics.  

Other values also apply to the design of tolerance concepts in automation. In manual assembly, it is easier for the worker to compensate for any tolerances. In automated assembly, for example, fixed screw points are always provided. If necessary, additional camera systems can be used to adjust the screw point relatively flexibly. However, the simpler and, above all, more cost-effective solution is the approach of keeping the tolerances small through appropriate component design. If possible, this should already be taken into account during component development.

Elaboration of various concept proposals and economic efficiency calculations as a basis for decision-making

It is often difficult at first glance to find the right balance between the use of workers and investment in automation technology. Especially when switching from manual assembly to automation, it is important for us to provide our customers with a very transparent breakdown. For this purpose, we work out several plant concepts in different degrees of automation, which our customers can use as a basis for their profitability calculations. For this purpose, we create a variant matrix taking into account the product start-up curve - including the possible use of workers, degree of automation, space requirements, necessary order deadlines and investment costs in the plant technology.

If necessary, plants are first planned with a higher proportion of workers based on the number-of-units curves and then automated step by step. This approach is not only particularly economical, it also gives the customer the opportunity to gradually familiarise himself with automation.

Prerequisites for plant commissioning and creating the infrastructure for automated production.

Not only is the question of the right concept crucial, we also determine the parts requirements for commissioning in advance and work out conclusive acceptance concepts for the plant together with our customers.

In addition, we provide our customers with the necessary information for plant relocation and integration into the production facilities. This includes, for example, the design of travel paths, the right unloading equipment or advice on the preparation of the complete infrastructure on site - such as specifications regarding interfaces to pneumatics and electricity or advice on the design of data management.

Intensive training and reliable service support facilitate entry into automation

We know that the entry into automation is a big change and, if necessary, also a certain challenge. To ease our customers' possible worries, we rely on a very intensive training concept, especially for the first automation projects, which we develop together with our customers.

Thus, a detailed introduction of the personnel in the areas of mechanics, electrics and maintenance ensures a comprehensive understanding of the system. The programmers receive in-depth training in the areas of PLC, robotics and image processing.

In addition, we offer a comprehensive service package, especially during the start-up phase of the plant, in order to be able to support our customers reliably. This also includes ensuring the service availability of sub-suppliers, such as screwdriver or robot manufacturers.

Your partner for the joint path to automation

Our aim is to provide our customers with comprehensive advice and support during their first automation projects: starting with the component design, through the decision for the right system concept, to the commissioning and operation of the system, including reliable training and service support - with AKE technologies as your experienced and reliable partner, your entry into automation is sure to work!