Custom machine manufacturing

Automatic riveting cell

Application area

Other industries

Customer's issue

Long cycle times, capacity increase, reduction of complaints

Machine purpose

To fully automate the riveting process of a flat sheet metal, eliminating human factors entirely.

Machine operation

Workers load the storage carts tailored to the cell with workpieces. At all times, one full and one empty cart are attached to the cell, each cart holding 20 workpieces. From this point, the process is fully automatic. The robot picks the workpieces from the cart in sequence using its vacuum gripper. It places the workpieces on an aligning table where they are positioned in the base position. The robot then re-grips the workpiece, moves it under the rivet feeder, where rivets are inserted, and riveting is performed simultaneously. The cell detects if even a single rivet is missing; in such a case, the product is placed on a reject table for inspection. Good products are placed by the robot into the empty cart. The cell enables full control of the riveting process and even allows for the repair of defective products. Additionally, the cell operates fully autonomously and requires operator intervention only once per hour for a few minutes to swap the full and empty carts.

Rotary Table Welding Machine

Application area

Automotive industry

Customer's issue

The large mass press tools regularly wore down from use. This lost material is typically restored by build-up welding, which is the task performed by this machine. Due to the nature of build-up welding operations and the heavy weight of the workpieces, there is a significant risk to the operator. It was important for the client that no personal injuries occur during the welding process and that the welding be carried out as efficiently as possible.

Machine purpose

Making the repair of press tools faster and safer.

Machine operation

Since every workpiece produced on the machine is cylindrical, the welding operation takes place while the rotary table rotates at a constant speed. The rotary table can be tilted up to 180° during rotation. The machine can access the clamped workpiece from almost every side, and the flux powder feeding is automatic.

Hydraulic press

Application area

Chemical industry

Customer's issue

Long cycle time, workplace safety

Machine purpose

Clamping products with a predefined force to perform manual assembly operations. Vertical pressing of seals into the valve housing.

Machine operation

Starting from the initial position, the operator pushes the valve into the working area of the hydraulic press. After selecting the type from the control panel, the machine closes the safety door and presses the product with a predefined force. The seat design allows manual rotation under pressure using a lever. In the rear position, the pressing head inserts a special seal into the valve housing. At the end of the assembly, the operator rotates the seat back to the starting position, releases the press, and pushes the product forward to the testing station.

Deburring and washing machine (automatic)

Application area

Automotive industry

Customer's issue

High cycle time, process reliability

Machine purpose

The main task of the semi-automatic machine is to deburr the inner holes of castings, then wash and dry them completely.

Machine operation

The operator places the casting into the prepared fixture, vertically aligns it, and manually locks the upper nest using a manual lever mechanism. If the casting is incorrectly positioned, the machine issues an error signal. The cycle is started using a footswitch, upon which the door automatically closes. A hydraulic cylinder secures the part from above, while a flange seals the five side nozzles. The system circulates washing fluid through the part at 15 bar pressure, while a rotary burr tool passes through the internal bore from below. After processing, the washing stops, and the machine dries the product inside and out with compressed warm air.

Milling and bending custom machine

Application area

Automotive industry

Customer's issue

Manual subprocesses, high cycle time

Machine purpose

Cycle time reduction, consolidation of multiple operations into a single machine. Elimination of error possibilities.

Machine operation

The Axis Roller bending-milling machine is a multifunctional device. One work cycle consists of three simultaneous steps: milling/deburring, bending, and inspection. The milled workpiece is placed into the SOLIDUR jaws of the upper bending machine. After placement, a new prepared workpiece is loaded into the lower milling unit. Once the bending is completed, the finished product moves to the sensor-based inspection unit.

Thread inspection device

Application area

Automotive industry

Customer's issue

Manual inspection, high cycle time

Machine purpose

The high number of defective parts that passed through the process, as well as the introduction of a new product with a large production volume, justified the transition to automatic inspection.

Machine operation

The equipment can inspect three different products, with 2–3 threads per product. The operator selects the specific inspection tasks from the machine’s program. The cycle time is 27 seconds, significantly reduced from several minutes previously. The changeover time between products takes a few minutes. On the HMI control panel, the operator must select which part to inspect.

Automatic clamp assembly machine

Application area

Manufacturing of electrotechnical products used in the construction industry

Customer's issue

High cycle time, many separate subprocesses

Machine purpose

Due to the product range and quantities, cycle times needed to be reduced (to 6 seconds per piece), and individual subprocesses had to be consolidated into a single machine.

Machine operation

The machine’s task is the automatic assembly of clamps. It presses strips of three different lengths (215 mm, 410 mm, 570 mm) into clamps, inserts washers into the pressed clamps, and screws in two M6Gx18 screws. The operator loads the main components and strips into the machine. Pressing, washer insertion, and screwing are performed automatically by the machine. Restocking components is the operator’s responsibility.

Rail welding robot cell

Application area

Automotive industry

Customer's issue

High cycle time, high defect rate

Machine purpose

To automate the rail welding processes in order to reduce cycle times and ensure process reproducibility, thereby eliminating errors caused by human factors.

Machine operation

The machine features two workstations, each equipped with a jig capable of holding three workpieces. The workstations operate independently. While one station is used for loading and unloading workpieces, welding takes place at the other station. According to the machine’s program, the welding robot alternates the welding operations between the two stations.