Automotive Component Assembly Cell

The brief. An automotive component manufacturer needed to scale output of a high-volume assembled part without sacrificing quality. Manual assembly couldn't hold the cycle time or the consistency the OEM demanded, and there was no reliable way to prove every unit had been built correctly. They needed a compact, repeatable cell that could keep pace with volume and stand up to a demanding quality audit.

What we did. Automation Republic designed, built and commissioned a turnkey assembly cell around coordinated servo motion and robotics. Codian Robotics delta robots handle fast, precise pick-and-place from feeders into the assembly nest; a PROMESS servo press performs the critical press-fit under full force-and-position monitoring, so every insertion is measured against a signature and flagged if it strays. AFAG feed and handling modules present components consistently, and poka-yoke checks — presence, orientation and verification sensing throughout — mean a wrong or missing part stops the cycle rather than reaching the customer. The cell was built in our in-house panel shop, safety-guarded to current standards with elobau safety devices, and handed over fully documented.

The platform. We built the cell on B&R — ACOPOS servo drives and X20 I/O over POWERLINK give the tightly coordinated, real-time motion that fast, accurate assembly demands, all engineered in one Automation Studio environment. The PROMESS press-fit monitoring gives a full graphical record of every join for traceability. As always, we remain vendor-flexible: the same cell can be delivered on Siemens, Rockwell/Allen-Bradley, Mitsubishi or Beckhoff to match your plant standard.

The result. Cycle time dropped and throughput rose, with quality locked in by design — every press-fit monitored, every part verified, every reject caught in the cell. The customer gained a repeatable, auditable process with the traceability automotive supply demands, plus clean documentation and code they own outright. VPN remote support keeps the cell tuned and updated without waiting for a site visit.

Scaling an assembled automotive part? Let's design a cell that hits your cycle time and your quality target together.