AUTOMATION

MANUFACTURER-INDEPENDENT & OBJECTIVE

Complete or partial trades?
You can expect a lot from us in the automation of industrial production – from the linking of individual production systems including handling components and comprehensive body manufacturing expertise to painting and final assembly for the automotive industry and its suppliers.
As a manufacturer-independent control system supplier, we integrate various systems into existing infrastructures.

COMPLETE SYSTEMS
MANUFACTURING SYSTEMS
MATERIAL FLOW SYSTEMS
ROBOTICS
SIMULATION

ROBOTICS

We test the application

We develop an optimal, individual configuration scheme in advance: we carry out tests for a wide variety of applications on the different robots in our in-house technical center.
Many years of programming practice and the sum of our experience in simulation and offline programming guarantee loss-free implementation in practice.
In addition, the commissioning of the systems is drastically shortened and therefore cost-effective.

VIRTUAL COMMISSIONING

because it works

Virtual commissioning is not only a key component of quality management in automation; it also offers the possibility of stress-free, efficient, and resource-saving project execution.
The arguments are manifold: long, expensive commissioning abroad, undesirable long working days in a temporary construction site workplace, discussions about the process and functionality of the system when it should actually have been running for a long time, or risky changes to a system without knowing what consequences they may have on the process…
All of this can be avoided with a simulation from SAR!
We offer various systems for the best possible coverage of requirements from all areas.

MATERIAL FLOW SYSTEMS

the solution for the entire logistics

Logistics solutions from SAR ensure the perfect flow of materials between production stations, from the receipt of raw materials to the finished product.
They cover the entire functional range from partially or fully automated warehouses to conveyor technology.
Based on material flow simulations, we develop the production buffer for intermediate storage of the finished products.
Connecting the customer’s own IT and logistics systems facilitates integration into existing structures.

REFERENCES

PRO
JEC
TS

Automatic hole closure for bodyshells

Fully automatic cavity preservation in automotive production

Pacesetter for electromobility

Battery tray assembly at the BMW Group plant in Regensburg

PRO
JEC
TS

BRO
CHU
RES

Light metal foundry

CNC machining with robots from design to production

Augmented Reality – get real with SAR

Augmented Reality

Handling heavy high-voltage storage systems

The high-voltage storage systems used in the automotive industry usually weigh over 1 ton.
SAR automates the complete handling of the heavy storage units, from automatic truck unloading in stacked transport boxes to assembly.
The empty containers are loaded back into the trucks for reuse.

Capacity utilisation analysis using material flow simulation

In the more complex injection molding sector, the number of work steps is so high that cycle time analysis is extremely difficult.
In order to check whether the number of robots is sufficient to meet the cycle times, SAR relies on the “Plant Simulation” material flow simulation.

Virtual commissioning (VIBN) wheel attachment

This system in final vehicle assembly takes the wheels configured by the customer from the pre-sequence provided by the supplier to match the vehicle that has just been completed.
The wheels are conveyed to the assembly line and fitted semi-automatically, taking into account different torques and wheel theft systems.
The entire system was tested and optimized using simulation.
This simulation can be seen in the video.
The findings from the digital twin could be transferred 1:1 to the real system.
This eliminated the need for all the usual optimization loops.
High system availability was guaranteed immediately after commissioning.

Remote maintenance, support and workflows

In the area of remote maintenance and support, AR enables us to achieve shorter and more cost-effective response times.
In the area of “workflows”, infrequent or complex maintenance tasks or the training of new employees can be significantly supported by AR.

Virtual commissioning (VIBN)

The system for a car manufacturer includes the first activities in final assembly, such as removing doors, scribing the chassis number, installing suspension struts and punching the front wall.
The short commissioning time of 2 weeks for the complete renewal of the electrical system to the current state of the art, including the connection of higher-level ERP systems and MES, was challenging.
The entire system was tested and optimized using simulation.
This simulation can be seen in the video.
The findings from the digital twin could be transferred 1:1 to the real plant.
This eliminated the need for all the usual optimization loops.
High system availability was guaranteed immediately after commissioning.

Automatic hole closure for bodyshells

In cooperation with well-known manufacturers of adhesive pads (tesa in the video), SAR has automated the application of the pads to openings in body shells.
SAR’s “automatic hole sealing” is characterized by significantly higher precision and process monitoring compared to the conventional method.

Automated application of hole seals

Hole seals are required in numerous positions and in a variety of designs in the bodywork.
Due to the manual process, precise and media-tight assembly is prone to errors and can lead to water ingress and corrosion.
FAIST ChemTec and SAR have developed a system for the automated sealing of car body holes that can be used by OEMs during the painting process.

SAR white sausage robot

Our SAR Weißwurstroboter shows various technologies that we work with on a daily basis in our projects: Conveyor technology, gripper technology, 3D image recognition, cooperation between several robots, etc.