Assembly Automation

We have gained a wealth of experience in planning and implementing industrial assembly systems and obtained results from numerous research projects on assembly automation with robot systems. We develop for you and in collaboration with you, fully-automated or partially-automated solutions tailored to your assembly requirements.


Services

  • Identification of technically- and economically-feasible automation potentials in your assembly
  • Development of innovative assembly processes and corresponding tools and systems for your assembly tasks
  • Process assurance by means of feasibility studies in our optimally-equipped assembly laboratory
  • Design of partially- and fully-automated assembly lines for your products, taking your specific general requirements into account
  • Development of software solutions for controlling assembly processes and analyzing the necessary sensor data


Technologies and innovations

  • Sensor-controlled joining processes using force-torque sensors and 2D and 3D cameras
  • Safety concepts and interaction concepts for assistive robots to enable human-robot collaboration
  • Programming methods and user interfaces for intuitively programming assembly tasks
  • Assembly of flexible components

 
Advantages

  • Lower costs through automation
  • Reproducible high quality
  • Increased manufacturing capacity
  • Enhanced ergonomics through reduction of physical stress on workers
 

Analysis of Automation Potentials in Assembly Processes

Fraunhofer IPA has developed the Automation Potential Analysis (APA) for this very purpose. Using a range of criteria, the automation experts examine the different assembly steps (separation, handling, positioning and joining) in terms of their “Fitness for Automation”, before weighting these various criteria according to customer requirements.

 

Assembly Processes and Tools

In order to automate assembly tasks, a tailored suitable automation process has to be developed in line with the necessary assembly tools.

 

Sensor-Controlled Assembly

Integrating sensors into robot systems for assembly allows positioning and component tolerances to be compensated for, thus doing away with the need for expensive component-specific devices for defining the position of parts.

 

Safe Human-Robot Collaboration with Assistive Robots

Assistive robots, i.e. robots that share the working environment with humans, enable assembly tasks to be partially automated even in cases where full automation is not economically practicable.

 

Automatic Component Analysis with NeuroCAD

The web-based software NeuroCAD automatically analyzes specific component properties, such as how easy a component can be separated or picked up.



 

"Design for Disassembly" Workshop

Design for Disassembly already takes the life cycle of a product into account during the development and design process and enables sustainable product design in line with the circular economy.

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Automated assembly of mounting rails with »pitasc«

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Flexible assembly process with pitasc

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Automation Potential Analysis-App (APA-App)

Assistive robot for riveting operations

Vollautomatische Applikation von selbstklebenden Türdichtungen mit Roboter

Konzeptstudie zur Mensch-Roboter-Kooperation zur Applikation einer selbstklebenden Türdichtung

Sichere Mensch-Roboter-Kooperation in der Montage

SMErobotics Trailer Video

Nieten, schrauben, klipsen: Viele Anwendungen. Eine Lösung.

INSITU – Intuitive und sichere Bedienung und Steuerung von Roboterassistenten

 

“DeMoBat” - Industrial disassembly of battery modules and electric motors

The aim of the joint research project is to demonstrate the feasibility of dismantling of battery modules and e-drive units in an automated process and on an industrial scale, taking economic and regulatory conditions into account.

 

ReNaRe - Recycling - Sustainable Resource Ultilization

The aim of the project is to automate the disassembly of future electrolyzers. For this purpose, the requirements of a digital twin as well as of the necessary software and hardware are identified at an early stage. Based on this, the project partners will design a robot-based disassembly system and demonstrate it for a process step using a real setup.

 

Automation Analysis and Concepts on Robots in Aseptic Production

Development of an overall concept for a robot-based automation solution in aseptic production for SKAN AG.

 

Force-controlled assembly of rail mounts with pitasc at WAGO

Together with WAGO, researchers from Fraunhofer IPA built a test scenario to demonstrate the extent to which robots can assemble terminal blocks on rail mounts with the “pitasc” software.

 

Product sheet “Assistive robots for assembly operations”

 

Product sheet “Automation potential analysis for assembly processes”

 

Product sheet »Assessing the potential to automate assembly processes«

 

Product sheet “Assembly planning: we'll develop your automation solution”

 

Product sheet »Implementing robot applications safely with and without HRC«