🎥 #ProjectSpotlight Assembly and Testing System for High-Voltage Distribution Boxes ⚙️

A quick look into our latest successfully completed project – an assembly and testing system for a high-voltage distribution unit – developed, manufactured, and commissioned by our team at Brainware Solutions GmbH.

The Task – Precise Assembly and Testing with the Highest Requirements
For use in upper business-class vehicles by a renowned German car manufacturer, our customer assembles a highly complex component – the high-voltage distribution box. Taking into account the expected production volumes, budget, complexity and automatable steps of the assembly process, available space at the production site in Romania, and many other factors, we developed a tailored concept.

Our Solution – A Coordinated Master-Slave System with Smart Technology
The result is an ergonomic, process-reliable workstation system for the semi-automated assembly and testing of the product, designed in a master-slave configuration. In this setup, the overall system is physically divided into two units for flexible integration into local shopfloor layouts. Additionally, the two subsystems can be easily separated and operated independently if needed.

The Highlights – Stable Processes and User-Friendly Operator Guidance
• 27 work steps with full process data logging
• Force-displacement monitored pressing processes up to 12 kN for reproducible joining
• Camera and sensor systems for part identification and assembly validation
• Electric screwdrivers with position control portal for standard-compliant screw connections
• Ergonomic single workstation with ESD-compliant surface
• Tool monitoring, automatic screw feeding, and live camera support for operators
• Control via industrial PC with touchscreen and our automation software vCheck®
• Comprehensive Poka Yoke validation for error prevention and process control

Need support optimizing your processes?
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