Automotive industry
Automotive automation for OEMs and suppliers.
For carmakers and Tier 1 and Tier 2 suppliers we deliver robotic stations, assembly lines and vision systems that cope with round-the-clock production and a customer audit alike. From the first concept to series production, with a single accountable supplier.
Zero defects is not a slogan. It is a customer requirement.
Automotive automation in Slovakia and the Czech Republic sets a higher bar than other industries. Lines run three shifts, cycle times are short and every part must have a traceable origin. A single defective part that reaches the carmaker means a complaint, stock sorting and often penalties as well. That is why we design automation not just to detect a defect, but to stop it from ever reaching the next operation.
Our engineering team has worked for the automotive industry since 1993. We have delivered vision-based body type identification before painting, before primer application and in a robotic sanding cell, error-proofing at eleven gearbox assembly stations, automated lines for assembling and testing seat locks, door type detection, retrofits of welding units for steering components and 3D location of profiles for a robotic bending machine.
We build the solution from components you already have in the plant, so your maintenance team does not have to learn yet another system. We connect the robot, camera and PLC to the existing line and send traceability data to your MES or database. We plan extensions to a running line in stages during shutdowns, so production does not stop for longer than necessary. After start-up we remain available with 24/7 service and remote access, because an automotive line cannot wait until the next day for a technician.
Typical automotive solutions.
Automotive assembly automation
Assembly stations and lines with robots, pressing, riveting and screwdriving. Every operation is checked and the result is stored against the part's serial number.
Body type identification
A camera compares the body with the data carrier information before painting, primer application or sanding, so the robot never starts the wrong program.
Assembly error-proofing
Cameras at assembly stations verify the presence and type of each component against the recipe. Until the operator clears the error, the system will not release the assembly.
Traceability with DMC and OCR
Reading DMC codes, laser marking good parts and archiving the parameters of every part in a database for audits and complaints.
Part variant recognition
A laser sensor, camera or 3D scanner identifies the part version before the cycle starts, and the station runs the right program without operator input.
Machine retrofit and certification
New control, control panel and HMI for units imported from abroad, resolving CE non-conformities and adding new part variants to an existing line.
What we deliver to automotive manufacturers.
A complete station or part of it, always with documentation and responsibility for the result.
- Concept, simulation and cycle time verification before production
- Mechanical design of stations, fixtures and grippers
- Electrical design, control panels and safety to EN ISO 13849
- PLC, HMI and robot programming including offline simulation
- Vision systems, sensors and DMC code readers
- Connection to MES, database and traceability system
- CE documentation and customer acceptance of the line
- Commissioning, operator training and 24/7 service
Technologies in our automotive projects
How the cooperation works.
Consultation
We come to you, look at the operation or the brief and tell you what makes sense. Without obligation.
Concept and quote
Technical design, scope, schedule and price. Always with a reserve for what practice reveals.
Implementation
Engineering, manufacturing, installation, programming and commissioning. One team, one responsibility.
Operation
Operator training, documentation and a service contract according to how critical the technology is for your production.
Related services.
Machine vision
2D and 3D vision inspection for quality control, OCR and DMC code reading, error-proofing and traceability.
Robotic cells
Turnkey robotic cells: design, safety, grippers, programming and commissioning.
Line retrofit
Modernisation of machines and lines: new controls, drives, sensors and safety with minimal downtime.
Frequently asked questions.
Did not find your answer? Write to us and we will reply within 24 hours.
How much does automotive automation cost?
It depends on the scope. Adding a camera to one station is a completely different investment from a new robotic assembly line. The deciding factors are the number of operations and part variants, the required cycle time and the connection to higher-level systems. We give a fixed price after the technical concept, not a rough guess.
Can you add vision inspection to a running line?
Yes. We connect the camera and its evaluation to the existing PLC and HMI, modify the program and verify everything during a planned shutdown. This is how we added body type checks to the robotic cells of a paint shop, for example.
What is error-proofing and when does it pay off?
Error-proofing, also known as poka-yoke, technically prevents a defect from passing to the next operation. It pays off wherever several variants of similar parts are assembled or where a defect would otherwise only surface at the customer. We most often implement it with a camera or sensor and a cycle interlock in the PLC.
How do you ensure part traceability?
Every part receives a unique identifier, usually a DMC code or laser marking. Against it we store inspection results, torques, measurements and production time in a database or MES. In the event of a complaint you can trace the exact batch and parameters.
Which robots and PLCs do you work with?
KUKA, ABB, Fanuc, Stäubli and Universal Robots, and both Siemens and Rockwell Allen-Bradley PLCs. If the carmaker prescribes a component standard, we follow it.
Do you provide service after the line starts up?
Yes. We offer warranty and post-warranty service, contract service with 24/7 standby and remote access. For continuous production we also agree regular preventive maintenance and spare parts for critical components.
Tell us about your line.
Send us the part type, the number of variants, the required cycle time and what is causing you problems today. We will get back to you within 24 hours with an initial solution proposal and a free consultation.