Today and tomorrow! Quick and flexible assembly and testing:Strama-MPS standards ensure efficiency and productivity.

Strama-MPS Maschinenbau GmbH & Co. KG

Ittlinger Straße 195 · 94315 Straubing

Tel.: +49 94 21 73 9-0

Fax: +49 94 21 73 9-2 47

vertrieb@strama-mps.de

www.strama-mps.de

Assembly and testing technologyProMoCell®

MonFlex®

ProMoChange®

ProMoScript®

8-station rotary table machineProMoCut®

Machining technology Cleaning technology

Cleaning machine ProMoClean® and robot cell RoboClean®

1 2 3Assembly and testing technology

ProMoCell® – the Strama-MPS standard assembly cell

Assembly and testing technology

Assembly and testing technology

ProMoChange®

quick-change system

ProMoScript®

laser marking system

Strama standards represent the whole process chain

Strama-MPS Standards

Strama-MPS develops customized ma-chines and equipment as well as stand-ardized products and components. Integrating these two worlds maximizes the benefits to our customers: individu-ality, high flexibility, high throughput, future viability and efficiency. Over one third of our team in engineering and project management works daily

to further develop and optimize the suitability of our standard components in everyday operation, such as the standard assembly cell or the MonFlex® AGV System.Please refer to pages 4 and 7

for more information.

Strama-MPS can look back on a dec-ade-long history in testing technology. So you will find our gearbox test rigs in the automotive industry as well as in the petrochemical industry all around the world. But we are also involved in future-oriented sectors such as photo-voltaics, with a sun simulator for solar modules among other things.

The integration of testing equipment into assembly systems has a key func-tion in quality assurance. We check a wide range of different parameters such as pressure, efficiency, torque, current and voltage characteristic, temperature, friction, vibration or torsional rigidity.Read more on pages 12 and 13.

Assembly systems

Our user-specific complete solutions, including control and measurement technology, range from manual work-stations via interlinked equipment down to highly automated produc- tion systems with integrated testing.

Together with its subsidiary AuE Kassel, Strama-MPS offers comprehensive solutions for all production tasks con-cerning the axle, the chassis and similar matters. We integrate mechanical equipment, electrical systems, control engineering, IT and logistics seamlessly and rapidlyRead more on page 8.

Our engineering always considers the overall processes. This saves our cus-tomers time and money and ultimately results in real added value: optimum performance, maximum output, higher profitability as well as variability in type changes and production of small and medium-sized series.

We integrate machining, cleaning, as-sembling and testing in one continuous process. The benefits to you? You have just a single contact person and prepare your specification only once. You avoid interfaces and keep modifications and adaptations to a minimum.

Together with you we keep pushing the boundaries of what is technologically feasible. Put us to the test!

Moving the limits together. Constantly.

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you will leave the competition standing through the intelligent integration of man and machine.

the challenges are productivity, flexibility, efficiency and wide variety in configuration.

Today

Tomorrow

Testing equipment and systems

ProMoCell®

Equipment productivity significantly increased

Modular and flexible Standards save costs Examples of system modules■ Locating module ■ Control module ■ Process module ■ Robot module ■ Test rig module ■ ProMoChange® (workpiece carrier

quick-change system)

Station I: Feeding of door part and placing into workpiece carrier

Station II: Feeding and joining of bush

Station III: Feeding, joining, checking of hinge pin and washer

The ProMoCell® modular assembly system offers 1001 possibilities for assem-bling and testing! The different compo-nents of the system modules allow any scalability of assembly lines and a quick and cost-efficient adaptation to changed basic requirements. The range of appli- cations goes from single stations to com-plex assembly and testing equipment.

A switch cabinet module with control panel is connected to the central base unit, the locating module. The locating module can be flexibly adapted to the size of the products to be machined. The specific assembly and testing pro-cesses are implemented on process modules. It is no problem to interlink single cells in a linear manner. The Pro-MoChange® quick-change system for changing the workpiece carrier ensures minimum non-productive times in the functional units and is compat- ible with all common transfer systems.

A strict separation of process, basic de- sign and control allows a flexible adapta-tion to customer standards and different control concepts. Product-dependent specifications are a feature of the machine concept, as is the focus on the highest possible degree of standardi- zation.

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■ Typical workpiece weight: up to approx. 20 kg

■ Workpiece carrier sizes: 80 mm × 80 mm to 320 mm × 400 mm

■ Cycle time: > 2 sec

■ Control: SIMATIC S7

■ Optional control systems: Beckhoff, Bosch-Rexroth

■ Cell size: 1200 mm × 1500 mm to 2400 mm × 2000 mm

Technical data

■ 1 operator (without logistics)

■ Cycle time for 2 pieces approx. 6 sec

■ Availability per single process > 99%

■ 16 different type versions

Technical data

Assembly line passenger car module hinges

Hinge assembly line based on the ProMoCell® standard assembly cell

Assembly threaded pin Feeding and assembly bolt

ProMoCell®

Example of system modules

Example hinges

Station IV: Riveting Station V: Feeding and joining

of box section and threaded pin

Station VI: Torque test and labeling

Station VII: Parts output

ProMoCell®

The standard assembly cell

Guard

Panels Base

Basic module

Process module plate

Constantly moving the limits! This assem-bly line for passenger car module hinges is a perfect example of how Strama-MPS engineering is pushing the technical limits and increasing output significantly. With short cycle times for small parts such as module hinges it is worthwhile to optimize the non-productive time even in the range smaller than a second, which is why the innovative ProMoChange® quick-change system was used.

The flexible design of the machine is suitable for a lot of types and different components can be machined without retooling. The single process steps are implemented in modules. Type informa-tion and component status are auto-matically written to a data memory of the workpiece carrier. For an optimum quality assurance the torque character- istic curves of the NOK components are recorded in-line and stored.

Panels

Switch cabinet modules

Locating modules

Process modules

Feeding of door part Feeding and joining of bush

Feeding, joining, checking of hinge pin and washer

Feeding and joining of box section and threaded pin

Torque test and labeling

Parts outputRiveting

Assembly and testing as integrated process

We meet even the most complex requirements

Integrated processes keep the assembly lines moving! The in-line measuring systems signalling faulty processes early on are of course a key factor for quality assurance and equipment efficiency.

The Assembly and Testing Systems busi-ness unit devises integrated inspections combined with manual work systems, interlinked equipment or highly auto-mated production systems.

Connecting: e.g. laser welding, friction welding, ultra-sonic welding, resistance welding, inert gas-shielded welding, clinching, wob-ble riveting, beading, joining, pressing, inductive soldering, bolting, plastic injec-tion moulding, gluing, punch riveting or hot-gas stamping

Dosing: e.g. greases, oils, glues and sealing compounds

Measuring and testing: Light, pressure, forces, paths (pneu-matic or electrical), acceleration, torques, weights, noises, magnet flux density, volt-ages, currents, resistances, leak tightness, flow rate, temperature

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■ Dimensions 1 m × 1 m × 0.6 m

■ Power supply by inductive coupling with additional battery pack

■ External communication via WLAN or TCP/IP protocol

■ Tracking via camera

■ Positioning accuracy: 3 mm in direction of travel, 1 mm at right angles to the direction of travel

■ Large speed range: 1.5 m/min - 30 m/min

■ Curve radius < 1 m

■ Safety scanner with switchable protection zones

Technical data

Highly flexible MonFlex® AGV system

Processes assembly technology

MonFlex® highly flexible AGV system

Process inert gas-shielded welding

Marking: Laser marking, labelling, scribe marking, dot peen marking, inkjet printing, hot stamping, notching, pad printing

Image processing: Contour and position detection, sample detection, measuring, text detection, bar and data matrix code

Inductive soldering

The Automated Guided Vehicle (AGV) allows a flexible setup of order-picking and assembly areas and interlinking if required. Combined with an AGV host computer an active routing with traffic control is made via the host computer, the vehicles communicate via a WLAN connection in real time.

Contactless power transmission takes place using an inductive system. Additionally, the AGVs are equipped with a 24V battery pack. Due to optical tracking the circuit is adaptable to changed requirements very quickly and with very little effort.

JIT and JIS material flow

Assembly rear axle

Assembly knuckleAssembly strut and swivel bearing

Together with its subsidiary AuE Kassel, Strama-MPS offers compre-hensive solutions for all production tasks concerning the axle, the chassis and similar matters. We integrate mechanical equipment, electrical systems, control engineering, IT and logistics seamlessly and rapidly.

This system sets the principle of continu-ous assembly in motion. In all assembly areas the wrench units move continuous-ly along on a guide system and go back to the home position upon completion of the assembly procedure. The wrench control recognizes right-left components, checks the bolts for defects and in this case starts loosening automatically.

In this modularly extendable line the knuckles for passenger cars are assem-bled. In small quantities the machine can be operated by one worker. In case of higher quantities up to three work- ers can be accommodated on each workplace.

Product life cycles, and consequently also the lifetime of equipment, are get-ting shorter, which often makes full auto-matic assembly lines uneconomical. So that manual assembly remains profit-able even in high-wage countries, pro-cessing times must be reduced, material flow optimized, the highest quality ensured and the process reliability increased.

This assembly line for strut and swivel bearing proves that these requirements are achievable even at absolutely com-petitive investment costs.

In the strut preassembly that is loaded manually, the single parts are bolted automatically. Via gravity conveyor the assembly area of strut and swivel bear-ing is efficiently linked to both strut and swivel bearing assembly stations where manual assembly of the swivel bearing is implemented with the automatic bolting station.

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■ Workpieces: assembly of strut

■ Electromechanical joining, force/path controlled

■ Q-data to control system

Technical data

■ Workpieces: rear axles

■ Cycle time: 90 sec

■ Working hours: 2 shifts/day; 5 days/week

Technical data

■ Workpiece: knuckle (driveshaft, swivel bearing)

■ Electromechanical pressing in 100 kN

Technical data■ Workpieces: assembly of strut

and swivel bearing

■ Cycle time: 40 sec

■ System cycle time: 84 sec (for the assembly lines)

Technical data

Workpiece carrier with strut Rear axle assembly and components for rear assembly

Angular ball bearing pressed in, retaining ring installed and dust shield pressed on

Gravity conveyor

Expertise in axles

Station I: Pressing in the angular ball bearing with an NC joining unit

Station II: Joining of driveshaft

Station III: The driveshaft is drawn into the hub by means of an NC joining unit

Station IV: Peening of the collar nut

Process cycle

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Assembly lines tripping device and final assembly line circuit breaker

Quality from A to Z

Wire flaming Feeding spring and bimetallic support

Thimble closing, wire cutting

Joining coil – bimetallic strip – bimetallic support – armature – spring – laser welding bimetallic strip

Reworking placeWIG welding wire – bimetallic support

Joining contact with contact support

Wire testing, thimble closing, WIG welding bimetallic strip – contact, spring force testing, ageing

Here, the comprehensive production know-how of Strama-MPS proves very advantageous: Two preassembly lines as well as a final assembly line for circuit breakers were integrated to create an efficient and future-proof solution.

The result is an overall project with impressive performance: outstanding cycle times, very high product quality as well as flexibility due to the automatic machine changeover to 85 type versions.

Final assembly line for circuit breakers

Preassembly lines tripping devices for circuit breaker and spring terminal (U-bolt and CC springs)

All variants from both preassembly lines are brought to the final assembly line for assembling, marking and testing of a total of 85 different circuit breakers. Parts feeding is made fully automatic via feeding systems, a palletizer and robot handling.

The full-automatic preassembly line consisting of 7 modules produces bolt- in circuit breakers and the pre-product of a tripping device in spring terminal design, which is completed in a second preassembly line with spring terminal and U-bolt. In the process the U-bolts are welded onto the connection of the complete tripping device (laser welding) and the CC springs are installed into the U-bolt.

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Robot with multi-component gripper

■ Pneumatic and electric motor-driven pressing processes (partially with force-path monitoring)

■ Wrench systems with torque-rotation / torque angle monitoring

Processes

■ Functional and calibration tests (power, voltage, breakdown, make-and-break cycle)

■ Laser marking inline

Preassembly line tripping device for circuit breaker

Range of parts for circuit breaker Circuit breaker

Fully automatic setting and testing

Different test procedures

2 in 1! Intelligent testing systems reduce costs while enhancing quality at the same time.

Circuit breakers are set and tested on this fully automatic machine. Parts are fed and unloaded by means of a conveyor. NOK parts are deposited on a separate belt. In the machine the workpiece carrier is conveyed on a linear feed system with workpiece locations. Thermal disconnection point of the circuit breaker is adjusted on four test benches, between them there are two stations each for cooling. Another test bench is used for magnetic testing.

■ Flow rate■ Leakage■ Pressure■ Suction pressure■ Speed■ Torque■ Hydraulic efficiency■ Overall efficiency■ Characteristic curves■ Pressure pulsation

■ Operating / release time■ Travel■ Break before make (non-overlapping)■ Current / voltage■ Contact indicator■ Bounce time■ Overvoltage protection■ Humming

■ Current / voltage characteristic curve■ Force / path characteristic curve■ Hysteresis■ Acceleration■ Speed■ Trip time

■ Current / pressure characteristic curve■ Hysteresis■ Dynamics■ Regulating behaviour■ Pressure / current phase shift

■ Electrical characteristics■ Electrolytic test■ High-voltage test

■ I/U characteristic curve■ Electrical characteristics■ Efficiency■ Shunt busting■ Light soaking

Test criteria actuator module Test criteria contactor Test criteria pressure control valve Test criteria gear pump Test criteria solar cells Test criteria sensor elements

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■ Connected load: 3×400V / 50Hz

■ Control voltage: 24 V

■ Compressed air: 5 bar

■ Output: 425 pieces/shift

■ Simatic control S7-300

■ TP 170-B touch panel operation

■ Test currents up to 600 A for thermal testing up to 3000 A for magnetic testing

Technical data

Measuring and testing technology

Test rig O2 sensor

■ Workpiece carrier loading

■ HIT (heater interruption test)

■ Electrical test (measurement and evaluation of voltages in mV, of currents in µA)

■ Electrolytic test

■ High-voltage test

■ Impregnation

■ Preheating

■ Functional check

■ Removal and oven transfer

■ Baking oven (final baking-out)

■ Magazining

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Conditioning and testing line for sensor elements

■ Supply pressure > 6 bar

■ Working pressure 5 bar

■ Oil-free operation

■ Dimensions: 19.8 × 4 × 2.80 m

■ Integrated workpiece carrier station

■ Alternative loading and unloading in magazines or blisters

■ Cycle time: 2 sec per sensor element

Technical data

Conditioning and testing line KPL1

Sensor elements

Heating station

Workpiece carrier loading

■ Cycle time >10 sensor elements/hour

■ Manual loading

■ 20-fold workpiece carrier

■ Contacting devices

■ Module 1 for electrical testing, continuously lean running, tests

■ Module 2 for electrical testing, continuously lean running, tests

■ Module 3 for electrolytic test, tests

Technical data

In contrast to a comprehensive quali- ty inspection, only the essential quality parameters are measured in SPC tests. Prior to the start of large-scale produc-tion the functionality of newly developed components is tested on specific test rigs or random checks are made during series production. For a lambda sensor manu-facturer Strama-MPS developed and built a test rig for the approval of O2 sensors. In the process the electric functional vari-ables are measured and electrolytic treat-ments carried out. The test is made on product-specific measuring cards. Short and long-term statistics can be evaluated via Strama-MPS’s standard software.

Putting quality to the test

Test rig O² sensor

A lambda sensor measures the oxygen content remaining in exhaust gases of combustion engines. Only the optimum combustion air-fuel ratio allows a complete combustion of the fuel and consequently the catalytic exhaust gas cleaning.

In the production O2 sensors for lambda sensors are subject to a multi-stage test- ing and conditioning process. For this Strama-MPS designed and built a machine constructed in modules, with 12 stations for step-by-step capacity expansion.

Stages of the machine

Testing for the environment