Munich. Important trends do not change from one day to the next. For example, it has been observed in assembly and handling technology for some time that an increasing number of companies are searching for modular systems that provide the optimum balance between flexibility and profitability. Progress is achieved in intensive development work conducted year after year, which makes a noticeable difference in practical applications. The latest solutions will be presented at the leading international trade fair for automation and mechatronics, AUTOMATICA 2010, which will take place on the grounds of the New Munich Trade Fair Centre from 8 to 11 June 2010.

Flexible systems both in assembly as in the test facility area are indispensable when producing industries have to react economically and quickly to fluctuations in numbers of pieces, changes in the degree of automation, development of variants and production relocations. Especially when systems must be operable after a short time, the benefits of flexible systems become obvious. Assembly expert Franz Plasswich, Division Manager and officer with statutory authority for the Automotive Division at teamtechnik GmbH, also points out the cost aspect: "In the current economic situation, the trend is increasingly to refitting existing systems instead of investing in new acquisitions. This can be achieved relatively easily and inexpensively with modular assembly systems."

But flexibility has many faces. It refers not only to the assembly process itself. Jean-François Bauer, Head of Marketing and Business Development at Mikron Assembly Technology in Boudry, Switzerland, expanded on this with another technological aspect: "The flexibility of feed technology is often decisive for the overall flexibility of a system, for example, when it is a question of the number of varieties. The required assembly speed also plays a role with respect to flexibility. It makes a big difference whether 20 or 60 cycles per minute are required. In addition, there is the complexity of the assembly process. These factors set limits to the achievable flexibility." How a complex assembly process affects the achievable flexibility of a system can be illustrated using the example of an igniter for airbag gas generators. Because a wire with a diameter of 0.02 mm must be processed here, it is more a question of repeatable preciseness than of flexibility.

Flexibility provides many kinds of advantages

Flexible assembly systems provide numerous possibilities. For example, they make it possible to increase an investment successively. This means that the user first relies on a minimum system configuration at the start of production. With increasing numbers of pieces and type variants, this system can then be expanded to adapt to the new production requirements. Another advantage is the shorter delivery times, which are made possible thanks to the combining of existing components. Individual modules or processes can be implemented parallel and only combined with the platform at the end.

Flexibility is also required in developing assembly lines. To keep the time until their products are introduced to the market, many companies already design suitable production and assembly systems during the development stage. As a result, system suppliers often only have planning sketches about the production environment of a system or about the product, which contain many uncertain variables when they submit bids. Then requests for changes increase during project realization. Additional process steps have to be built in or the sequence of processes has to be changed. This can be done more easily using a modular system than with a completely linked system, especially when flexible project management also exists with the possibility of simultaneous engineering.

Finally, modules that have been standardised need not be developed anew for each system. Tried-and-tested and with a continual improvement process, their use increase process reliability and consequently maximum system availability. The lower costs for a system put together in this way round out the numerous advantages. It's not surprising that many mechanical engineers strive to design this type of system.


Many assembly tasks require special solutions

It can be observed at the same time that assembly tasks often require a very special solution from design engineers, for which they have to think in completely new dimensions. "Consequently, many of our member companies still consider themselves consciously as special purpose mechanical engineers and have accepted the batch size of 1 for their systems as inevitable," stated Daniela Dietz, responsible for assembly and handling technology in VDMA Association Robotics+Automation. While standard modules exclude many special requests, users can really go to the limit at such special purpose mechanical engineers. It is important there that both sides deal fairly with additional demands. For example, the machine supplier has the possibility to provide a clearly defined scope, within which requests for changes are covered in the system price. If the system is already half finished and the customer comes with new information, which makes substantial adaptations necessary, the mechanical engineer should formulate an offer for the changes immediately. Additional costs and new delivery data must be included in the offer, and the customer agrees to this with his signature.


Practical examples from the automobile industry

This procedure saves work for whoever bets on modular design, at least for the most part.

The example of the "Teamos" system from teamtechnik for assembly and checking electric engine components illustrates the possible development of a modular system. Three variants were initially produced on the system: one product from the automotive area and two products for industrial technology. A host computer was installed at the start, which coordinated the logistics for the three variants. After additional components for standard engines were included in the system within the framework of revising production, it was used to full capacity during multiple shifts. The market situation changed later, and the planned number of pieces for the automotive product decreased. To use capacity, the customer then included additional products from industrial technology in the system. The variants were created for this in the host computer, and the necessary interchange parts were coordinated. The number of pieces increased again at a later time, and new orders from the automobile sector were also received. Consequently, the degree of automation was increased; the system was expanded correspondingly with basic components and set up with a new process sequence. Today, more than 14 basic types with at least 10 sub-variants are produced on it. "The flexibility to react to changed market requirements with expansions and changed process sequences was only possible from an economic point of view with a modular system," Franz Plasswich concluded.

But he admits that not every assembly and test task requires high flexibility. "It would be counterproductive to insist on a modular system for applications that can be handled more economically using conventional designs. As a result, we also still offer conventional systems to have the right solution in our range of products for every application." Jean-François Bauer agrees that it is not solely a question of flexibility: "All aspects have to be considered in establishing the ideal relation between flexibility and productivity. After all, the users need above all a solution that makes them competitive."


AUTOMATICA – Platform of leading system specialists

As a highlight at AUTOMATICA 2010, visitors will find the greatest concentration of suppliers of turnkey assembly systems in Europe at this time. A majority of the assembly system suppliers from Germany and Switzerland as well as numerous renowned suppliers from outside of Europe will present their products. AUTOMATICA attains a top spot in Europe with the presence of leading system suppliers from Germany, Switzerland and Austria.

Jean-François Bauer is convinced of the merits of AUTOMATICA: "It is a very significant trade fair for Mikron, because if fulfils our needs in many respects. We appreciate the provided platform, which is very representative for our range of products and services. In addition, the schedule every two years fits well to our business model. The infrastructure of the trade fair is good, and the organisation as well as the hall layout are very attractive and efficient for visitors. For these reasons, we have decided to concentrate on AUTOMATICA in 2010 as the only topic-overlapping trade fair."

Module specialists and special mechanical engineers will exhibit together at the trade fair. "Assembly and handling technology is the part of automation where everything comes together," Daniela Dietz explained in this context. Companies producing robots and machine vision systems are included here, who will also exhibit their innovations in Munich. This contextual interrelation will also be reflected in the structure of the trade fair; the halls are consciously not occupied one behind another in a row, but instead next to each other. This arrangement makes it possible for visitors to experience the elements of automation technology while circling the halls.


AUTOMATICA, International Trade Fair for Automation and Robotics
AUTOMATICA is the international trade fair that brings together all areas of robotics and automation under one roof. It has been held every two years at the New Munich Trade Fair Centre since 2004. The aim of the fair is to present the entire value-added chain in robotics and automation. The industry-driven concept for AUTOMATICA has been developed by Messe München GmbH and the conceptual sponsor of the fair, the robotics and automation division of Germany´s engineering federation (VDMA). Exhibitor and visitor statistics for the AUTOMATICA trade fair are audited by an accountant on behalf of the Gesellschaft zur Freiwilligen Kontrolle von Messe- und Ausstellungszahlen (FKM, Society for Voluntary Control of Fair and Exhibition Statistics). AUTOMATICA is a 'UFI approved' international event, a certification awarded by the Global Association of the Exhibition Industry.


Messe München International (MMI)
Messe München International (MMI) is one of the world´s leading trade-fair companies. It organises around 40 trade fairs for capital and consumer goods, and key high-tech industries. Each year over 30,000 exhibitors from more than 100 countries, and over two million visitors from more than 200 countries take part in the events in Munich. In addition, MMI organises trade fairs in Asia, Russia, the Middle East and South America. With six subsidiaries abroad – in Europe and in Asia – and with 64 foreign representatives serving 89 countries, MMI has a truly global network. Via its six subsidiaries – in Europe and in Asia – and 64 foreign representatives actively serving over 90 countries, MMI has a worldwide business network. Environmental protection and sustainability are key priorities in all MMI´s operations, at home and abroad.
Further information: www.messe-muenchen.de


Press contact:

AUTOMATICA
Claudia Huber, Communication Manager
Tel. (+49 89) 949 - 20862
Fax (+49 89) 949 - 20869
Email: claudia.huber@messe-muenchen.de


VDMA Robotik + Automation
Daniela Dietz, Assembly and Handling Technology
Tel. (+49 69) 6603 - 1530
Fax (+49 69) 6603 - 2530
Email: daniela.dietz@vdma.org
www.vdma.org/assembly




Flexible assembly systems contribute to helping producing companies master numerous challenges economically with respect to fluctuating numbers of pieces, development of variants and production relocations.
Photo: teamtechnik



Processes can be replaced and expanded thanks to modular setup.
Photo: teamtechnik



Mikron has been concentrating on building high-speed assembly systems with standardised modules for more than 15 years. Individual modules can be replaced or expanded simply with the current G05 platform.
Photo: Mikron



A typical module of a Mikron assembly system is a station for wire welding.
Photo: Mikron



Not only technology plays a role in assembly and test systems; service also plays a significant role.
Photo: teamtechnik



The higher the production volume, the more interesting automated assembly is – even with higher investment costs.
Photo: Mikron