Axle Assembly

Variant flexibility? Variable throughput? Fast amortisation? Flexible staff allocation? Our solutions for your axle assembly systems are as flexible as your requirements. Axle assembly is one of the specialities of AuE Kassel GmbH. Whether it is standard processes such as bolting and joining or integrated on-line or off-line processes, AuE has a comprehensive approach to completing all axle assembly tasks.

Low-investment axle assembly

High availability and flexible staffing, factoring in all quality requirements, are the advantages of AuE's low-investment assembly systems. The degree of automation is usually low and reduced to the essentials. In any case, all requirements to the assembly of serial products are met. Higher-lever assembly control systems as well as archiving properties that are relevant to quality are part of the turn-key solutions offered by AuE.

Areas of application:

  • Medium and small volume series production (e.g. prototype or pilot production)
  • Absorbing production peaks / supplementing series production

The axles are usually assembled on non-machine-driven assembly dollies with integrated workpiece carriers (MMP - non-driven mobile assembly platform). For maximum flexibility, the conveyor technology can navigate freely or be delivered in a guided, rigidly linked version. All process steps needed for axle assembly (e.g. bolting, joining, mounting, measuring, aligning, etc.) can be integrated. 

As the staffing is flexible, you can, for example, have an axle assembled by only one worker (worker pushes the assembly dolly through the entire plant), which leads to a higher degree of identification with the product and increases productivity.

The typical cycle time is > 2 min.

This type of system is being used by Daimler and Audi, among others. 

High-volume axle assembly

Maximum productivity combined with a degree of automation that is adjusted to the individual requirements are the main features of our systems for volume-oriented series production. Poka Yoke measures prevent assembly errors. Ergonomic tools are also as much of our area of expertise as system configuration and design – including clocking the individual work stations to guarantee maximum manpower utilization. The unlimited JIS capacity is possible here as well.

The most commonly used technology for conveyors and workpiece carrier transporters, as well as in continuous flow production and stop-and-go operation:

  • Different variations of roller and chain conveyors
  • Spur belt with workpiece carrier return on the slack side
  • Circumferential conveyor technology
  • Traversable low-floor belts
  • Special solutions, e.g. rotating stages

The workpiece carriers have been designed according to ergonomic and logistic criteria. Pick-to-light, with or without access control, spatial allocation of threaded connections, and plausibility checks by scanning components are only a few of the measures used to ensure 100% quality.

The typical cycle times are between 30 and 90 seconds.

Such systems are being used at Audi, VW, Opel, and Daimler.

Highly flexible axle assembly

Shorter vehicle development cycles and flexible production models increasingly require flexible axle assembly systems. Highly flexible plant concepts make it possible to produce several different types and variants of axles in batch size 1, taking the strict requirements on quality, ergonomics, material supply, and logistics into account.

Especially for adaptive material supply, AuE offers consistent solutions from planning to implementation, for example the supermarket principle or transporting the material with an MMP mobile assembly platform. The MMP, developed by AuE, is based on self-driving vehicles with a flexible track guidance concept (optical or inductive). As they have a battery, they can be autarkic, at least for a limited time. Ideal accessibility and almost complete design flexibility bear additional advantages. The integrated workpiece carriers can be easily adjusted and expanded for all kinds of variations.

The degree of automation of highly flexible axle assembly systems by AuE can be chosen freely depending on the respective requirements. AuE designs holistic solutions that include assembly control, MMP guide control, and interfaces with higher-level systems. The cycle times are between 60 and 200 seconds. Systems of this type are being used by VW, Daimler, and GM-Holden, among others.

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