Our new semi-automatic line in total length of 57.5 meters was manufactured for the assembly of air conditioning units for the new BMW electric cars. The line consists of assembling and testing station, which are seamlessly connected. In the semi-automatic assembly part, two robotic workstations are designed for component loading and the other two are used for automatic screwdriving, which is secured by screwdriving systems from JHV-SOLUTIONS.

Test part of this assembly line is completely automatic. Here occurs a pressure test, the dimensions of the connection points are verified by a 3D camera, and the correctness of the assembly is checked by camera robotic workplace. Also the noise of the unit is tested in different load modes. After completing all the tests, the finished air conditioning unit is moved by the robot to the transport box.

This fully automatic production line is used for handling of various types of metal sheets and final metal parts. The whole process begins with the metal part alignment, straightening and its subsequent labeling on the inkjet printer.  The robot arrives with suction cups and the prepared part is vacuum-picked and transfered to the burning table, where the printed shapes are burned with a laser.  The manipulator selects the cuted parts and places them on the belt conveyor. The remaining metal sheet waste is separated and disposed.

This new semi-automatic line assembles and tests the fire detector buttons. An interesting feature of this line is the 3D printed tricky shaped bearing, in which individual parts are placed. The operator places this bearing in a pallet on a belt conveyor, which transports this parts through all assembly and testing stations. In these stations is the unfinished part handled from and to the central conveyor by a 6-axis robot. The input parts required for assembly are taken from vibrating feeders by two 4-axis robots. From the output conveyor are the final parts removed by an operator, who finally checks and packs them. 

We have delivered a new sorting machine, which is used to bakery crates check-in. Columns of crates are inserted into the machine, which calculate them and load on the driver’s account, as the machine communicates with the company’s internal system. An important function is the counting mechanism, which recognizes different types of crates in a wide range of qualities (from new crates to unusable). Subsequently, the crates travel to the dishwasher area, where they are removed with the help of staff, as the dishwasher is not part of the equipment.

We delivered new semi-automatic palletizing system for removing metal sheets from containers. This machine was designed for air conditioning manufacturer as universal machine with the possibility of connection to any type of CNC bending or cutting machine. The operator only chooses the removal and loading procedure according to the metal sheet type. The whole system is equipped with a 6-axis robot, which secures the sheets handling from the pallet to the CNC machine. Depending on the metal sheet type, the system adjusts the position of the robot, the location of the vacuum “suction cups” and the force of the vacuum needed to remove and store the metal sheet in the KLT tray. This KLT containers come to robot automatically from the double-deck conveyor, which serves also as containers storage.  

The new fully automatic robotic cell is designed for automatic insertion of various types of inserts in sizes from M1 to M24 into plastic moldings. The machine is equipped for fully automatic operation. Bar feeders from our subsidiary JHV – SOLUTIONS are used for inserts feeding. The robotic workplace is supplied with a 6-axis robot in the JHV design and equipped with an automatic robot calibration. On the loading tables is possible to place a 1200mm x 400mm sized product. A new innovation from the FESTO company is used in the machine – a pneumatic MOTION terminal enable the control of pneumatic pressing cylinders.

This new semi-automatic assembly and testing line, with the help of two operators, completes and subsequently tests the control rails for the interiors of electric cars. The line is equipped with ultrasonic welding and fully automatic vacuum screwdriving supplied by our sister company JHV – SOLUTIONS. The line also includes a complete test station simulating the movements of the driver or passenger. The entire line is connected to the MES system and the Beckhoff system is used for control. In the spirit of Industry 4.0, the line is already equipped with a module for remote maintenance and online diagnostics as standard.

We are installing a new 20m long line at Škoda Auto in Mladá Boleslav. It is used for pre-assembly of components for the MQ200 gearbox. The line consists of a total of 11 stations, four of which are pressed using a combination of servo and ball screw with forces up to 50kN. There are one main and three secondary conveyors on the line, where the components are loaded into pallets. These components are further transferred by a robotic manipulator to a pallet on the main conveyor, where the assembly itself takes place. A total of 3 manipulators (SCARA Staubli) and one 6-axis KUKA robot are used. At stations with SCARA manipulators, there are camera controls that check the correctness and installation of the part from the side conveyors.

These automatic lines are used to mount the internal ball joint IBJ. They are designed as universal, with the possibility of producing more types of IBJ joints. Loading and unloading is solved fully automatically using SCARA robots and pneumatic manipulators. Both lines are designed for 1 operator with a 20 – 30 minute car autonomy. The operator only refills the input components to the vibrating feeders.

The new production line is designed for fully automatic operation and is used for the production of segmented elbows from a tube with a diameter of 250-280-300-315 mm. The machine is able to create bending angles from 15 ° to 90 ° by tilting. To operate the line, one operator is required, whose task is to load the required sheets into the station, which then continue along the roller conveyor to the station for bending. The most interesting thing about this machine is that so far nobody has been able to build something like this.

The new automatic assembly control line will complete and test car displays. In the first phase, “blisters” are inserted into the line with components, from which the display is gradually assembled and then checked. The line is operated by two operators, one of them connects the flat wires from the display to the PCB. The second operator performs a visual inspection and removes the finished products from the line. All other manipulations are then secured by Kuka robots.

The automatic line is used for cold rolling of wires at a speed of up to 4 m / s and their subsequent processing by cutting into brushes. The line consists of several stations. There is a gradual hydraulic bending of the sheet metal envelope and then assembly with a bundle of wire and brush shape calibration. The line is equipped with an air-conditioned overpressure switchboard and other elements that enable long-term operation in an environment with airborne steel dust. There is also included a robotic workstation with a Yaskawa GP50 robot with a gripper for gripping and trimming wire ends.

We manufactured a new semi-automatic production line for Austin Detonator in Vsetín, which produces electronic detonators. This production line is 14 meters long and compiles 3 types of connectors and 3 types of wires. The Bosch conveyor, 6-axis robot ABB and ESD Scara Staubli are the parts of this production line. Operator is at the entrance, where establishes input parts and also at the exit. Approximately from the middle around the product is explosive atmosphere V1.

We delivered new automatic robotic cells for our customer in automotive industry. The stations are designed for subsequent processing and packaging of metal sheet stampings from the upstream press. The delivery included two identical workstations, each equipped with one SCARA robot for handling parts, a palletizing station for KLT trays with sorted parts. The stations are designed as fully automatic without the need of operator intervention. In this case, we used a Mitsubishi PLC and an operator panel from the same manufacturer to control the robotic cells.

This semi-automatic production line is used for the production and inspection of switches for the 5th door of the car. As in the previous year, with regard to the coronavirus situation, the installation was carried out in compliance with all hygienic regulations. The line is designed as a semi-automatic with a closed conveyor loop. Due to the return, the loading of parts is handled by a manual workplace, other assembly and inspection stations are automatic. For pneumatic and electric drives we used again FESTO supplies.

An automatic line for smoke sensors assembling arrived to the Romanian customer. Due to the coronavirus situation, part of the line was installed remotely, thanks to the possibility of using Mainware smart maintenance. The line consists of a total of 4 modules. The components are first equipped with PCB LEDs and a thermistor. Then follows the soldering station and first tester. The second module contains a parts storage, where the individual parts dry. In the third module, the entire product is completed and continues to the second tester. From there, the product is moved to the fourth module, where it is packed in a box along with a paper manual.