Located in the Amberg industrial park in Upper Palatinate, about 70 kilometers from the Czech border, Baumann Automation develops custom production platforms for robotics, assembly, handling, and testing technology. Their standardized automation cells meet flexibility, scalability, and 100% customization. “We ensure that the customer’s needs and our solutions are a perfect match,“ says Michael Klaus, Project Manager for Assembly Solutions at Baumann. “Our mission is to deliver the best machines, and for that, we need the best components.” Many parts of the Baumann’s systems are equipped with SCHUNK products, including grippers and change systems. Recently, the special machine manufacturer from northern Bavaria faced a particularly challenging task: Designing a screw assembly cell with extremely compact dimensions to fit precisely into an existing production line. “We needed to integrate five screw stations and two handling units within an exceptionally tight space,” explains Project Manager Klaus. “It was a matter of millimeters; the limited space was a constant consideration. After an intensive engineering phase in collaboration with SCHUNK, we achieved an optimal solution: using the SLD linear direct axis with five independently movable slides for the screw units.
A 1.81 meter-long SLD linear direct axis mounted on a steel beam, spans horizontally across the whole width of the cell. Five high-precision guided slides travel independently along this axis. Each slide of this X-axis is customized for application-specific movement. Each slide on this X-axis is equipped with a universal LDN linear module from SCHUNK, mounted via an adapter plate. The LDN module, featuring an X-profile, direct linear motor, and roller guidance, moves along the Y-axis. Attached to each LDN module is a screw spindle as the end effector, which performs the screwing process along the Z-axis.
At the start of the screw assembly process, the workpiece – a pre-assembled pump module – enters the screw assembly cell on a workpiece carrier via an infeed conveyor from the left end. At the cell entrance, a barcode label on the component is scanned, retrieving all stored product data. A stationary, vertical handling module then uses a suction gripper to automatically remove the component lid, placing it on a secondary conveyor that carries the lid along in parallel until it is reattached. Next, the lid-free housing is indexed through four screw stations, where various screws are inserted into the housing, and a circuit board is secured. A second stationary vertical handling unit with a suction gripper then picks up the lid from the secondary conveyor and places it back onto the housing. At the fifth and final screw station, the lid is fastened in place. Finally, the pump module is discharged from the cell on the right end. Integrated quality monitoring within the spindle ensures flawless screw connections. In the event of a screw defect, the faulty part (NIO component) is automatically ejected. The production cell operates fully automatically, 24/7; manual intervention is required only in case of malfunctions. For this purpose, Baumann designed the basic cell module “ro|box” to be highly accessible and easy to operate.
The five screw stations move independently along the SLD axis. This allows the different screwing processes to be precisely coordinated, ensuring that all screw processes are completed reliably. This is the foundation for the pump, an important product for modern and environmentally friendly energy technology, to be passed on with high quality to the next production station of the pump manufacturer. “The robustness and precision of the SLD ensure flawless screw operations and ultimately help to avoid waste and scrap,” emphasizes Michael Klaus.
This SLD linear direct axis supports approximately ten to twelve kilograms on each of the five slides with adapter plate, LDN linear axis, and screw unit for the specific application. The high load capacity is possible thanks to the highly resilient profile rail guide – it ensures exact process. Each slide or linear motor has its own controller. The TTK 70S non-contact linear encoder measures absolute position and speed with maximum precision. “Thanks to the integration of the motor and safety features, and the resulting compact design, we were able to resolve our space constraints with the SLD,” says Project Manager Klaus. “Otherwise, we would not have been able to fit the entire screwing process within the two 1.60-meter cell sizes.”
The installed SLD 11 linear direct axis, a configurable standard product from SCHUNK, was an excellent choice for Baumann in terms of cost-effectiveness. Users benefit from its modular mounting, installation, and combination options— for example, the SLD can be equipped with a brake and can be fitted with a cover belt. Depending on the customer application, the SLD can be outfitted with multiple active motor carriages, allowing for specialized axis solutions.
“We have truly implemented this challenging project hand in hand,“ confirms Michael Klaus. “This philosophy at SCHUNK is very beneficial to us at Baumann. SCHUNK has spared neither time nor effort in finding the best solution together with us. The result is unique, and our customer is delighted -overall it is a perfect match!”