Sat Sterling specializes in automated filling and testing systems in final automotive assembly, whereby the systems are always developed, manufactured and seamlessly integrated on a customer-specific basis. The high degree of customization results in tailor-made system solutions for all industries where systems need to be filled with different fluids in a targeted and reliable manner. "This includes not only refrigerants, but also brake and servo oils, for example. We also design systems for initial fuel filling," says Carsten-Peter Hues, Head of Production at Sat Anlagentechnik.

Sat Sterling developed special systems for automatic coolant filling for a customer in the automotive industry. They make it possible to supply vehicles on the production line with both coolant and windshield washer fluid. The systems consist of two modules: In the basic unit - which does not have to be located directly on the production line - the temperature-dependent mixing of the coolant takes place before it is transported on to the so-called traversing unit.

"This automatically driven traversing unit is located directly on the production line. It accompanies the vehicle to the right or left of the conveyor belt and fills it with the appropriate liquids during the journey," explains Carsten-Peter Hues. "We are talking about a travel length of twelve to 20 meters, which is covered in 90 to 120 seconds." Due to these fast cycle times, a system can usually only fill every second car. Accordingly, at least two versions are required per production line; in most cases, a backup system is also ordered.

Ready-to-install Totaltrax complete systems are used in the filling systems. © Tsubaki

The traversing units usually move along rail systems that are attached to the ceilings of the production halls at a height of up to six meters. Their "lifelines" are the energy supply systems from Tsubaki Kabelschlepp, which supply the units with power. However, the chains also house various other cables and hoses for vacuum, compressed air, communication and, last but not least, the coolant. "In total, up to five media can be transported simultaneously in these special energy supply systems," explains Rainer Raschczyk, Technical Field Service at Tsubaki. "We supply the chains as ready-to-install assemblies - including cables and connectors."

The complete systems are based on MC1250 cable carriers. This is a robust plastic chain with aluminum separators. In this application, it is used in a gliding arrangement; the cable drag chains are fitted with glide shoes. The end customer in the automotive industry had precise specifications for the cables and connectors. A hydraulic package was also integrated into the complete Totaltrax system. "Apart from the customer-specific requirements, particular attention was paid to high reliability when developing the system," explains Rainer Raschczyk. "Sat Sterling systems must guarantee 99.9 percent availability - and this naturally also applies to the cable drag chains."

Plug & Play: Ready-to-install energy chain system
As a specialist in energy chains, Tsubaki has been a partner for customers looking for complete, ready-to-install systems for decades. "From simple ready-made chains to highly complex systems, we offer ready-to-install assemblies for almost any application," explains Rainer Raschczyk. "Optimized production processes and the timely provision of the right, high-quality components guarantee fast throughput times and save time and money, no matter how simple or complex the system is."

Sat Sterling has also made this experience. The filling experts used to assemble the cable drag chains themselves. "The procurement of cables, wires and hoses and their assembly, plus supposedly minor tasks such as labeling the products - it all takes a lot of time," recalls Carsten-Peter Hues. "We are very happy to be able to outsource this task to a professional in this field - because it allows us to concentrate on our core competencies again."

"Our Totaltrax concept as a ready-to-connect solution of perfectly matched components is in high demand, simply because companies need to continuously increase their efficiency these days," confirms Rainer Raschczyk. "We assemble and manufacture our individual solutions from a batch size of one and guarantee our customers consistently high quality."

The ready-to-install energy chain system is delivered just-in-time directly to the production facility or the desired place of use - safely transported in disposable or reusable packaging. The user installs the cable carrier system as an assembly on their machine or system and attaches the cable and hose connections, in line with the motto "Plug & Play efficiently".

A device for the safe transportation and assembly of the complete systems is currently being designed for Sat Sterling. The background: "The ready-made cable carrier systems weigh between 600 and 700 kilograms, making them difficult to transport and set up at heights of up to six meters," says Carsten-Peter Hues. "Tsubaki has already developed a temporary solution for us, which is already working very well. We are now in the process of refining it."

Werner Eul/as