It is a logical consequence: the automotive industry is increasingly shifting quality assurance in assembly to suppliers. These in turn demand that their automation partners create the technical prerequisites for this and also deliver ever faster. If mechanical engineering companies want to remain internationally competitive, they need intelligent subsystems that can be deployed at short notice for typical tasks. For example, for pressing and joining.

Founded 25 years ago, KMS Automation specializes in automation technology, fixture and special machine construction. Around 115 employees work at the company headquarters in Schramberg-Waldmössingen in the central Black Forest. The decisive impetus for the standardization of pressing and joining processes came from an inquiry from a global automotive supplier.

After an initially planned in-house development proved to be too cost-intensive, KMS Automation accepted the offer from its long-standing system partner Bosch Rexroth to participate in the continuous further development of the Smart Function Kit Pressing subsystem. "We couldn't pass up this opportunity," explains company founder and former Managing Director Peter Schneider. "The collaboration was very committed and constructive right from the start."

Standardization with smart servo presses

Within the system to be implemented, the Smart Function Kit forms the central component in the first of five assembly stations. The subsystem consists of the electromechanical cylinder, servo motor, drive controller, industrial PC and force sensor. In addition, KMS Automation also uses screw drives and linear guides as well as aluminum profiles from Bosch Rexroth in the assembly line. The primary task of the servo press is to electromechanically guide an approximately 250 mm long tube through the interior of an aluminum oil pan and press it into the intended fit with a defined force. The vehicle's drive shaft later runs through the additionally bonded tube. The second requirement was for the Smart Function Kit to monitor the joining process and forward the process data to a higher-level IT system for quality assurance.

Previously, KMS had mostly implemented comparable applications with high forces hydraulically, which was much more complex. "Such a versatile subsystem, which is supplied completely from a single source, will save us valuable time in the future, which we would rather invest in finding creative solutions," explains Peter Schneider's successor Klaus Wurster. "We see the biggest time savings in engineering and commissioning, and there are also standardization effects in purchasing and service," continues the new Managing Director. The modular approach of the Smart Function Kit enables KMS Automation to standardize applications in the force range from 2 to 70 kN. Variants with axial or parallel motor mounting ensure flexible integration into different system designs.

Flexible software development

The pioneering software features of the Smart Function Kit Pressing include a commissioning wizard, a module for graphical programming, a dashboard with information on the running process and a range of features for diagnosing, visualizing and evaluating the process. During the fully guided commissioning process, the software wizard automatically parameterizes the drive controller. The process is defined visually using prepared modules, which are simply lined up and assigned parameters using drag-and-drop.

Connection to the line control system via fieldbus is also quick and easy using a function module. The Smart Function Kit also supports the OPC UA standard. The Smart Function Kit offers further options for data access via analog and digital I/Os and a ReST API. Thanks to the open interfaces and the process information provided via them, the mechanical engineering company was able to implement the required quality assurance and documentation much more quickly and easily than before.

KMS Automation mapped the system's safety functions via a safety controller. Profisafe is used for safe communication between the safety devices and the Smart Function Kit. Among other things, this ensures that a defined, safe maximum speed is not exceeded. In the event that a person reaches into the surrounding light curtain, the transfer to a safe standstill is initiated and monitored.

Reduced complexity, time and costs saved

For Peter Schneider and his successor Klaus Wurster, the Smart Function Kit represents a fundamental step towards simplifying previously labor-intensive and costly tasks. "We can now map the majority of our systems purely electromechanically. This not only reduces the complexity of the machine design, but also allows us more freedom in process design with greater accuracy. Thanks to the finely adjustable electromechanics, we can use different speeds, among other things, which ensures quality and allows shorter cycle times. For example, we can use slow probing to check whether the workpiece is inserted and then press and join with high precision."

In addition to KMS Automation, all customers will also benefit from the software innovations introduced in the course of the joint further development, as Bosch Rexroth will make the updates available to download free of charge. Among other things, the next software release will speed up data storage, enabling KMS to further reduce cycle times. "We are delighted with the excellent cooperation and the extent to which we have been involved in the further development of the subsystem," summarizes Klaus Wurster. "The partnership with Bosch Rexroth is set for the future. In view of the far-reaching simplifications and time savings, we want to use the modular subsystems and proven components of our automation partner wherever possible.