At ZEITLAUF^® antriebstechnik, research is becoming ever more important. Because, as a company working in the technology sector, research is the key to innovation for us – and innovation is the engine of growth and success. With the Institute for Manufacturing Automation and Production Systems at the University of Erlangen-Nuremberg we have a strong partner on our side. Because the overall objective of the institute is that of crosslinking all the separate sub-functions of a plant into a computer-integrated overall concept. In so doing, particular attention is given to assembling devices with electronic and mechanical components to make up mechatronic modules.

The complex task
The objective of the latest research project was that of developing process and plant technologies for automating the assembly of crown gearhead units. An assembly cell was to be conceived and constructed that – based on a modular product concept – is suitable for carrying out assembly, adjustment and testing tasks on various crown gearhead versions. The system to be developed was intended to be capable of flexibly adapting to suit different versions (in terms of size, material pairing) and quantities. As measuring and adjusting processes are required at the end of the assembly process, human-process-cooperation was necessary. The cell was also to be able to be adopted into hybrid assembly systems without great adaptation expenditure. This was meant to create a future-proof assembly and plant concept that makes it possible to react flexibly to future versions and quantities.

The forward-looking solution
ZEITLAUF antriebstechnik achieved this objective in every respect:

• Successful taking into service of an integrated measuring/pressing cell for measuring and pressing at the same time in a single device.
• Developing, putting into practice and successfully evaluating a measuring principle using laser triangulation to a measuring precision of less than 10 µm per unit.
• Producing a labview-based control programme for all components, including a user-friendly GUI concept and graphically preparing the measuring signals for control by the operator during the process.
• Successful small batch production adjustment with outstanding results as regards smoothness and quietness, in some cases better than reference gearheads and sound patterns.
• Successfully applying the measuring and pressing principle to various versions of the EtaCrown^® angle gearhead with crown wheel technology in sizes 75 and 52.

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