The system developed by AS Automation assembles more than 100 variants of safety plug connectors and couplings from 21 different individual parts. The high number of design variants poses particular challenges: many small parts must be fed in, positioned and assembled with precision in a confined space.
AS Automation combines its experience in rotary and linear transfer systems to integrate multiple assembly processes – from mounting the base body and the moulded housing assembly to the final "marriage" of the components – into a compact system design.
A central component of this solution is the integrated MCS system (Modular Conveyor System) from Festo The handling system can be seamlessly synchronised with the assembly processes thanks to the path-controlled movements of the workpiece carriers.
The result: more precise processes, higher cycle rates and significantly increased processing performance. Festo also supplies a comprehensive range of automation components – from pneumatic drives to electric axes and innovative handling concepts such as the T-gantry – which can be used to design modular and scalable machines.
The close collaboration between AS Automation, ABL and Festo began as early as the concept phase. Thanks to efficient and rapid coordination processes, simulations carried out jointly, and the incorporation of expert knowledge, suitable components were selected and an economical and easy-to-maintain system structure was designed. ABL emphasises that the solution is not just technically impressive, but also meets the demanding requirements in terms of flexibility, service life and standardisation.
For ABL, the applied solution means more product variants with consistent quality, simplified commissioning, lower operating costs and easier spare parts supply. The modular structure allows quick adjustments to be made for new product variants, ensuring long-term competitiveness.
Seamless Automation is more than the sum of its individual components. Only the well-designed integration of handling system, controller and modular drive solutions – supported by partnership-based cooperation and the early involvement of experts – creates sustainable, efficient and flexible production systems. Festo acts as a key technology and integration partner, turning innovative automation solutions into industrial practice.
AS Automation, based in Bamberg, develops customised special-purpose machines – from feeding systems and high-performance assembly lines to end-of-line packaging solutions – and supports customers from the concept phase through to the delivery of turnkey machines. AS Automation, together with Festo, created a system that enables ABL to achieve an impressive range of design variants and high process density.