Leading local door opening products manufacturer ASSA ABLOY South Africa recently upgraded its assembly line to a semi-autonomous production system engineered by Petrichor Concepts, a recently acquired and wholly owned subsidiary of FLSmidth South Africa. Accurately moving components to each workstation across the assembly line is achieved using a Bosch Rexroth TS 2 transfer system supplied by Tectra Automation.

Aiming to increase its production output of a variety of different lock types and configurations, the new assembly line integrates a combination of automated and manually operated workstations connected via the 29-metre TS 2 conveyor.

“Simpler assembly tasks are now achieved with high-tech robotics, while jobs requiring more dexterity are achieved manually,” explains Trevor Bruce, Engineering Manager, Petrichor Concepts. “Bringing this lean production concept to life required a transfer system providing full 360-degree pallet movement, including lift stations, with ultra-precise levels of control.” With the TS 2 transfer system, components are moved to their required positions within a 0.01 mm tolerance.

Enabling this precise handling control across the system are pneumatic technologies from Aventics, including the AV05 control bank with Profibus connection, with 96 digital inputs and 48 outputs connected to Petrichor’s engineered control system architecture.

“In addition, the modular, fully customisable nature of the Bosch Rexroth TS 2 system enabled us to build a bespoke line with simplified engineering and installation requirements, and full technology support from Tectra Automation,” Bruce says.

This modern, ergonomic semi-autonomous assembly line now enables ASSA ABLOY to produce more locks per operator than before. In addition, enhanced quality monitoring across the assembly process and reduced wastage of materials and consumables helps further reduce production costs and time.

The TS 2: versatile, robust, adaptable

Comprised from standardised modular units that can be combined in many ways to create a single system, the Bosch Rexroth transfer system is designed for transport of workpiece pallets up to 240 kg, with several types of combinable conveyor media.

“The TS 2 is a system solution that can be scaled quickly and easily for any requirement,” explains Cobus Snyman, Technical Sales Representative, Tectra Automation. “Its adaptable, modular design allows factories to realise a vast array of system layouts with quick implementation, ideal for any assembly application, from the automotive industry, to electronics and electrical technology, medical technology and the optical industry.”

 Tectra Automation is a member of the Bosch Rexroth South Africa Group of Companies.