for the treatment of trims, armrests and seatbacks

As a technology-neutral manufacturer, we provide our customers with gluing and joining systems in all required degrees of automation. We combine many years of experience with power of innovation and absolute customer orientation. Newly developed processes are tested at AKE-technologies for their practical suitability in an extensive series of tests. The output is always a product with the highest level of quality.

Assembly-Laminating-Gluing System for the treatment and assembly of seat backs

System description

• System for fully automatic assembly of add-on parts on rear seat backrests and for sticking carpets on the seat back
• Inserting the metal structures and the backrest locks by the worker
• Automatic screwing of the backrest locks
• Automatic feeding and mounting of various bearing parts
• Picking up the carpets to be glued with robots from a magazine system
• Automatic insertion of carpets and metal structures into the rotary indexing table
• Apply glue to the carpets
• Heating and pressing of carpet and metal structure
• Automatic removal and component marking
• Documentation of all process data (torque and angle of rotation of screwing processes, carpet colors, temperature, amount of glue etc.)
• Automatic transport of all components during the entire assembly process

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Gluing system for trim parts

System description

• System solution as rotary indexing table with four processing stations and parallel processing of two components to increase production capacity
• Workplace protection via contact-less light protection system with step-back guard for ergonomic workplace design
• Manual insertion of various components by the workers
• Tool systems with component mounting molds and bonding systems for attached components
• Component mounting molds with integrated parts detection and locating
• Automatic adhesive application with two robot systems applied as a bead for the downstream automatic jointing process
• Monitored jointing and cooling process of the glued joints
• Separate monitoring of the adhesive equipment with cyclical check of the output and tool alignment
• Automatic component removal with a robot system and transfer function to the downstream system for further processing

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AKE technologies represents the system partner in the field of assembly of e-mobility components for its customers. We offer our customers experience in the development and manufacture of assembly-testing lines for complete battery systems in various degrees of automation, from the prototype line to fully automated series production. We advise our customers on automation, manufacturing processes, security concepts and much more, always taking their individual requirements into account!

Pre-series line for the assembly of battery modules | Combination of manual and automatic processing stations

General Information

• Combination of manual and, if necessary, automatic processing stations
• Flexible design thanks to intelligent processing modules
• Integration of set-up carts and exchangeable processing modules
• Extension and reduction of the number of modules in the event of changes in the number of units
• Complete data documentation and process monitoring

Processes

• Automatic feeding and start of line tests of single cells and cell modules in different variants round cells, prismatic cells, pouch cells, modules with prismatic or pouch cells)
• Plasma or laser cleaning of battery cells and pre-treatment of application surfaces: plasma, flame, laser, liquid, ...
• Assembling of the cells with monitoring of mounting force and distance
• Application of adhesives and gap fillers including process control with camera and 3D scanning systems
• Laser welding of contacts with process monitoring
• Scope of assembly in the HV state of the battery in special HV cells (interconnection of modules, HV tests, covering of open contact points)
• Leakage test of the fully assembled system (air, helium, if necessary subsequent filling of the battery with a cooling medium)
• End of Line testing (communication test, plausibility test, high voltage test, functional test)

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Automated assembly line for the production of battery modules from prismatic cells

General Information

• Processing of several cell variants on one line
• High demands on variant management
• Innovative transport systems for flexible plant design
• Combination of numerous individual processes in the smallest possible space
• Integrated emergency concepts in all process steps
• Process monitoring and data transfer to a higher-level production control system ensuring 100 percent traceability

Processes

• Begin of line testing to ensure processing of high quality components
• Cleaning and preparation processes on the cells, side and end plates (laser or plasma treatment, foil applications, camera inspections)
• Stacking & welding processes for battery assembly
• Pre-assembly and integration of the cell contacting system
• End of line testing (insulation and breakdown tests, cell temperature, voltage values)
• Component marking for traceability
• Automatic component output and packaging of modules

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Assembly line for the production of battery modules and pack production from round cells

General Information

• Automated assembly processes with integration of manual processing steps
• Pre-production of different module variants
• Intermediate electrical testing
• Flexible pre-assembly of battery packs
• Automated final assembly area for inserting the battery modules and carrying out the HV activities
• Possibility for later integration of an automated transport system into the manual pre-assembly
• Complete data acquisition and process monitoring

Processes

• Automatic feeding and processing of single cells (cell scan, testing, cleaning)
• Assembly of single cells to battery modules (joining, laser welding, intermediate electrical testing)
• Partially automated pre-assembly of battery cases and lids (combination of manual assembly and automatic screwing stations)
• Automatic joining of modules into pre-assembled trays
• High-voltage interconnection of the battery system
• Lid assembly and leak test
• Intermediate and end of line electrical testing
• Manual component marking and packaging

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AKE technologies is a manufacturer of fully automatic assembly lines for the production of cell contacting systems in e-mobility. Cell contact systems (CCS) are responsible for interconnecting the individual battery cells in electric vehicles. They differ in numerous features. Depending on the vehicle design and the requirements of the OEMs, there are different arrangements of the cells according to the space available in the vehicle, a parallel or series connection is possible. The cells are assembled into single or double modules and are suitable for use in hybrid vehicles (HEV / PHEV) as well as in purely electrically powered vehicles (BEV).

AKE's production systems offer an intelligent production concept to cover a wide variety of component variants without setup processes. Different cycle times can be implemented through scalable system concepts. Complete data acquisition and process monitoring takes place during production, which guarantees 100 percent traceability.


Image: Concept example of assembly system for cell connectors

In the following are examples of the processes that are integrated into our assembly systems for cell connectors:

Processes

1. Automatic feeding of various individual parts

• Busbars
• Power sensors
• Temperature sensors
• Housing and carrier parts

2. Component depending pre assembly of the busbars

• Equipping taps and sensors
• Assembling
• Laser welding
• Gluing

3. Mounting of the prepared busbars in the carrier parts

4. Ultrasonic welding and hot welding

5. Depending on requirements, combination with manual assembly stations (e.g. for cable assembly) or with rework stations

6. EOL testing

• High Voltage isolation tests
• Communication testing of the sensors

7. Component marking as DMX codes and text

• Labeling
• Laser marking

8. Automatic packaging in customer containers

• Trays
• Pallets

Scope of documentation

• Batch numbers of the individual parts
• Single part tracking of safety-relevant individual parts such as HV separations
• Mounting forces and distances
• Adhesive application parameters
• Laser welding parameters
• Camera measurement results
• 2D and 3D measurement results
• Test results from electrical tests
• General information about the produced part such as individual part number, production time, product variants, and much more.

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for the treatment of handles, arm rests, seat backs or trims

On all five continents, vehicle manufacturers use our compact and modular designed lamination technology. A tried-and-tested system design. material-saving concepts, automated processes and quick-change systems for maximum possible utilization make the highly reliable and low maintenance systems and tools from AKE-technologies a benchmark in the lamination sector.

Lamination system for loading floors

System description

• Compound system for mounting and processing loading floors in the trunk
• Assembly system with integrated press system and exchangeable tools
• Production of various component variants possible

Processes

• Free insertion of fabric decor and carrier part and automatic position detection by camera systems
• Plasma treatment of the folding area of the carrier part
• Application of a hot melt adhesive by means of a roller system
• Heating of the adhesive by an infrared heating field
• Laminating and edgefolding process integrated in exchangeable tools

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Gluing-Laminating-System for center armrests

System description

• Bonding of the fabric decoration instead of a complicated stapling process
• Inserting and positioning of the leather decor by the worker with the help of positioning aids
• Integrated plasma pretreatment
• Fully automatic gluing and edge folding
• Additional gluing of a cover
• Integrated adhesive application for gluing, laminating and edge folding processes
• Re-work-free edge folding
• Removable tool

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Lamination system with edgefolding process

System description

• Flexible system concept with four separate lamination edge-folding stations
• Variable deployment of workers (up to 4 persons)
• Workplace protection through vertical roller door systems to exclude unintentional process interruptions by the workers
• Manual equipping of the arm rest base carrier on the upper tools of the press systems
• Manual placing of the spacer fabrics with insert templates in the foam bed
• Manual placing of the leather blanks in the laminating tool with positioning of the stitching by laser pointer and vacuum fixing
• Automatic adhesive application with robot system in a spinning spray process for fixing the spacer fabric and the stitching to the base carrier
• Subsequent automatic lamination process in both tool systems
• Automatic adhesive application applied as a bead for the downstream automatic edge-folding process
• Circulating rework-free edge-folding process of the component edge
• Separate monitoring of the adhesive equipment with cyclical checking of the output and tool alignment

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for surface changing of arm rests, handles or trims

Dry anti-friction films open a range of possible applications for which we – together with customers and partners – always find the perfect solution. Anti-friction coatings are increasingly gaining in importance as a reliable design element. With its high degree of know-how in material comparability, AKE-technologies ensures the reduction of friction and wear, cleanliness and long service life.

System description

• Efficient coating of the parts by preventing overspray
• Reproducible, process-optimized coating process with fully-automatic robot control
•  Quality certification by cleaning station and flow control
•  Drying of painted parts by energy-efficient circulating air system
•  Replaces cost-intensive manual gluing-on of felt strips or similar materials
•  Huge savings potential in the parts price calculation for acquisition activities

For the surface treatment of instrument panels, center consols and trims

AKE-technologies has further developed flame treat technology in order to increase the surface tension of various thermoplastic materials, hence improving their adhesion. Space-saving designs and the intelligent control of all parameters minimize throughput times and costs. We place special value on safety during the flame treatment process. Consequently, all processes are seamlessly monitored and documented.



System description

• Flexible system concept with two separate flame treatment stations
• Manual equipping and removal of the base carrier for the instrument panel
• Automatic flame treatment of lamination surfaces for optimizing the adhesive adhesion with a robot system
• Tandem flame treatment tool with line and spot nozzles for optimum processing of the various surface geometries
• Quick-change component mounts

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When it comes to inner qualities

The passenger compartment reflects the character of a vehicle. High grade materials, carefully and durably finished, provide an especially haptic experience. Very special requirements in terms of accuracy, cleanliness and finishing quality are placed on production systems for interior parts.

As an innovative technology partner, we offer a complete product range for the processing of plastic, leather, artificial leather, fabric or carpet.

AKE-technologies has already supplied a number of different tools and systems for the production of interior components. We have continuously expanded and optimized our process technology in numerous projects for applications, e.g. on door panels, arm rests, handles, central consoles, column and luggage compartment trims as well as roof liners. Our customers benefit from these further developments by keeping processing technology at the latest status.
Depending on the need, we offer standard tools and systems, individual special solutions or complete production lines for the manufacture of interior parts.

Are you looking for a system for machining a special component?
Just contact us via our contact form!

Fully-automatic assembly system for the manufacture and testing of door catches

When assembling door catches, the systems from AKE impress with a cycle time of just 5 seconds. The feeding of the individual components via conveyor systems enables operation by only one worker and ensures system autonomy of up to two hours. Even a design for the assembly of different component variants is easily possible.



System description

• Compact design with accessible system platform and vertical protective door systems
• Flexible assembly concept with workpiece carrier system and parts handling by 6-axis robot
• Processing of all individual parts as bulk material with position alignment of the components and wrong part rejection
• Optical component detection and measurement by high-resolution camera systems
• Automatic greasing and riveting of components with process monitoring
• Torque checking of the relevant bearing points
• 5 second cycle time for the assembly of one door catch

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With the assembly test systems from AKE, the manufacture and testing of hinges is possible in shortest cycle times. The system technology includes production systems for a wide variety of hinge types from numerous areas of application.
The product portfolio ranges from production systems for tailgate or front lid hinges for a wide variety of vehicle types to door hinges and kinematic systems for various industrial sectors such as automotive, white goods or the furniture industry.

The assembly lines of AKE technologies are designed for the production of different hinge types on one system. Depending on the type of system, the hinge bodies are inserted with the help of a worker or automatically. Small parts are provided via conveyor systems with an autonomy up to 4 hours.

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Learn more about production lines from the field of assembly and testing technology:

AKE technologies is the experienced specialist for the assembly and testing of airbag components. Especially in this application, the test component is crucial to ensure an absolutely correct assembly of the components and thus the safety in the vehicle.

Fully-automatic assembly and testing system for airbag ignition units

System description

• Combined component, or material feeding as bulk material or magazined in trays
• System solution as rotary indexing table with various processing stations
• Automatic assembly of the igniter assembly with propellant dispensing
• Automatic dispensing of the sealant with UV curing and subsequent overpressure testing
• Batch-based data recording and communication with process control computer
• 4.8 second cycle time for the assembly of one airbag ignition unit

Fully-automatic test system for airbag igniters

System description

• Component feed magazined in workpiece carriers, component output as bulk material and sorted according to test results
• Integrated pressure chambers for applying helium (45 minutes at 15 bar) with automated workpiece carrier handling
• System solution as a rotary indexing table system with 4 processing stations
• Automatic testing of the airbag igniters with a helium leak checker in combination with high vacuum
• Component-based data recording and communication with process control computer
• 2 seconds cycle time for the testing of one airbag igniter
  

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Assembly line for manual-automatic assembly and testing of power distribution systems

When designing assembly lines for Power Distribution Systems, the modular AKE standard cell is often used. Workpiece carrier systems, robotics and monitoring systems designed individually for our customers promise flexibility and individuality within the standard concept.

General information

• Possibility to combine manual and automatic processing stations
• Design as a fully automatic production line
• Connection to upstream and downstream systems such as injection molding machines
• Simple integration of additional processing stations in the event of changed specifications, quantities and component variants
• Connection of the stations with conventional transport systems such as double belts, but also with innovative shuttle and linear drive systems
• Complete data documentation and process monitoring
• Possibility of integrating a central material station to reduce logistics routes

Processes

Automatic process examples

• Feeding of various components (housing, fuses, washers, screws, nuts, ...)
• Camera testings as incoming inspection of components (e.g. overmolding inspection of surfaces)
• Screwing of attached parts
• Clinching of electric components
• Mounting of components with end position, maximum force or force-displacement monitoring
• Hot welding and ultrasonic riveting processes
• Insertion of pressure compensation elements
• Laser transparent welding of plastic parts
• Leakage tests
• Mechanical EOL tests (e.g. actuation of mechanical assemblies)
• Electrical EOL tests (e.g. continuity and function)
• Optical 2D and 3D EOL tests (e.g. latching and measurements)
• Component marking with labels, inkjet printers or laser systems
• Automatic packaging of the produced components in customer packaging

Manual process examples

• Assembly of individual parts
• Packaging of the produced components
• Assembly of connectors and cable assemblies

Scope of documentation

• Batch numbers of the individual parts
• Individual part tracing of safety-relevant individual parts such as electrical separator elements
• Mounting forces and paths
• Torque and angle of rotation values of the screwing processes
• Camera images and results
• 2D and 3D measurement results
• Test results from the EOL tests
• General information on the component such as the individual part number, production time, product variants, and much more.

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Learn also more about our production lines for HV boxes:

Highly flexible WT line for the manual production of BMCes

General

• Design of the system as a manual workpiece carrier line
• The worker pushes the workpiece carrier with the component manually from station to station
• Changeable setup carts for material provision
• Fixed installation of the cost-intensive components on the machine frame

Processing station without component-specific setup cart

• Machine frame with docking station for the setup carts
• Fixed assembly of components that are required for several component variants (screwdriver, control panel, printer, hand scanner, camera systems ...)

Component-specific setup carts

• Component feeding for the individual parts
• Component-specific sensor systems
• Component-specific positioning aids and auxiliary tools

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Automated assembly test system for the production of BMCes

General

• ESD (Electro Static Discharge) design of the system
• Automatic tray feeders
• Worker guidance through laser projections directly onto the product
• 24 integrated robot systems
• Assembly of 179 individual parts to form a complete, tested battery management system in a cycle time of 39 seconds
• Production of different component variants for various vehicle types
• Integration of the customer's AGV system for linking the system parts and for connecting the production line to the logistics

Processes

• Screwing processes
• Application of a heat transfer compound
• Automatic placement processes
• Workplaces for wiring harness assembly
• End of line testings

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Semi-automated assembly test system for the production of battery management systems

General

• Implementation of very high cleanliness requirements
• Highly flexible transport system in cleanroom class
• compact system design on a small footprint

Processes

• Dispensing process with camera testing
• Screwing process with gradient recognition
• Laser welding processes
• Plasma and laser cleaning
• Resistance brazing and caulking
• Hardening of the adhesive traces using a conveyor oven

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Automated assembly test system for the production of battery junction boxes

General

• High flexibility with loop structure of the transport system
• Consideration of ESD (Electro Static Discharge) and TecSa (technical cleanliness) requirements

Processes

• Manual placement workstations with sensors
• Automatic screwing stations
• Pressing in the PCBs with force-displacement monitoring
• External pressing station for busbars with force-displacement monitoring
• Numerous integrated optical tests

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Learn also more about our assembly lines for power distribution boxes

Assembly plant consisting of welding and test cells for the production and testing of module connectors

When designing assembly systems for module connectors for electric vehicles, the issue of safety is of particular importance. Various HV and LV tests are integrated into our systems. Pure end-of-line testing systems for module connectors are also regularly implemented.

General information

• Different machine designs existing of different robot cells
• Component-independent feeding of the individual parts with flex feeders and belt systems with cameras to detect the position of the components
• Design as a test system or in combination with various manual and automatic processing steps
• Automatic change of robot grippers
• Integration of manual workstations (e.g. housing assembly)

Processes

Mechanical machining processes

• Welding of busbars
• Assembly of additional parts such as sockets and screws
• Assembly of housings
• Application of component labels

Testing processes

• Optical measurement of mounting brackets
• Optical testing of mold fillings and geometric characteristics
• Visual testing of the screwing surfaces to ensure that they are free of overmolding and damage
• Presence and variant testing of injected inserts
• Testing of screw lengths
• Testing of housing latches
• Component-specific HV insulation and breakdown tests
• Flexible component-independent HV insulation tests

Scope of documentation

• Batch numbers of the individual parts
• Mounting forces and paths in assembly processes
• Welding parameters
• Camera images and results
• Test results from the HV tests
• General information of the component such as the individual part number, production time, product variants, and much more.

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AKE technologies offers a wide variety of assembly systems for the production of charging technology in the field of e-mobility. The product portfolio includes production lines for charging sockets, connector systems, charging stations and much more.
In the area of high-voltage technology, careful assembly and subsequent testing of the components is crucial. In addition, the highest cleanliness requirements must be implemented and system components have to be designed ESD (Electro Static Discharge) compatible.

General information

• Assembly and testing of connector systems in a cycle time of 20 seconds
• Automatic feeding of attachment parts
• Processing of different component variants possible
• Integration of a flexible transport system according to cleanliness requirements in clean room class

Processes

• Automatic feeding of individual parts such as pins, boards, component carriers, housing parts
• Pre-assembly of individual housing parts
• Force-displacement-monitored joining processes of the housing parts including testing of the catch mechanism
• Applying a thermal paste with subsequent 3D testing of the application
• Laser transparent welding of housings
• Test processes: leak tests, HV and LV testing, insertion force testing
• Component marking

Scope of documentation

• Batch numbers of the individual parts
• Individual part tracing of circuit boards
• Joining forces and paths
• Torque and angle of rotation values of the screwing processes
• Camera evaluations
• 2D and 3D measurement results
• Test results from the EOL tests
• General information on the component such as the individual part number, production time, product variants, and much more.

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Assembly system for the automatic assembly and testing of charging cables

General

• System for the assembly and testing of AC charging cables
• Automatic feeding of cables, housings and attachments
• Automated removal and packaging station
• Integration of a flexible transport system with fulfillment of cleanliness requirements in clean room class

Processes

• Automatic unwinding, alignment, stripping and bundling of the cable as well as automatic stripping of the cable strands
• Crimping the different types of contacts
• Pre-assembly of housing and connector
• Integrated ultrasonic welding processes
• Test processes (leak test, electrical and optical tests)

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Learn also more about our production lines for HV modules: