Assembly Solutions
for Smart CONNECTIVITY

Assembly lines and test systems for high-precision and compact electronic actuators

Electronic actuators play a pivotal role in modern systems, transforming electrical signals into precise mechanical movements for compact applications.

These components are essential in fields like industrial automation, consumer electronics, and micro-mechanics, where tasks such as optical alignment or driving precision assemblies demand the highest accuracy.

XENON specializes in tailor-made automation solutions for assembling and testing these actuators. Leveraging technologies like electromagnetic and piezoelectric drives, our systems ensure top precision, fast cycle times, and adaptability to evolving production requirements.

Our key competencies for electronic actuators are:

  • High-precision assembly for compact actuator designs
  • Technology for clean and precise applications
  • Automated handling of diverse variants
  • Capability with Shape Memory Alloys (SMAs)
  • Handling of Ultra-Thin Wires
  • AOI for complex assemblies
  • Smart process data management
  • Integration into larger systems
  • General contractor for actuator solutions

High-Speed-Linear-Transportsystem

Original Image
Modified Image

System Capabilities

  • Maximum Flexibility

    • Flexible & Scalable Layout Options
    • Double/Bypassing of Processes
    • Use as singular WPC Transfer Changer

  • Effective Process Utilisation

    • WPC Change Time below 0,4s
    • Acceleration up to 4g
    • Maximum Speed up to 5m/s

  • High Process Stability

    • Accuracy up to +-0,01mm
    • use of WPC as additional process axis
    • Support for vertical process-forces

  • Suitable for Clean Room

    • Medical-Compliant for ISO-5
    • Stainless Steel covered Drives
    • No friction, No abrasion

Modular Concept

A mechatronic system containing all functions necessary for operation. A modular, fully integrated linear motor with power electronics and displacement measurement in one device. A mover as the moved part. A mechanical guide rail. The most diverse applications can be realised with these few coordinated components. The desired geometries, lengths and radii are formed by the number and choice of the components

Linear Segment

Image

Curved Segment

Image

Vorteile gegenüber konventionellen Lösungen:

  • Flexible und individuelle Carrier Ansteuerung
  • Ermöglicht Optimierung von Taktzeiten
  • Parallelisierung von Prozessen möglich
  • Hohe Positioniergenauigkeit
  • Teil des Handlings Systems
  • Keine bewegten Kabel
  • Wartungsfreier Antrieb

Rap Tra

  • Seit einem Jahr Grundsystem von Hoyer gekauft
  • Video Funktionsumfang für Website erstellen#
  • Individuelles Beratungsintesives System
  • Magnetischer Zahnriemen Motor
  • Kosten im Vergleich zum Wettbewerb

Warum sollte sich der Kunde für RapTra entscheiden
Auswahl Vergleichsdokument Auwahl Hoyer 

  • Vergleichswerte zum Wettbewerb (USP?)
  • X Achsen werden eingespart
  • Handlingeinsparung
  • Verssuchstand von Hoyer Folie nur in Blau bisher Umgesetzt
  • Puffer über Staustrecke möglich
  • Abriebfrei
  • Schnittstellen (Spec)

Key Benefits

  •  Controlled movement at all times and all places on the transport path. No jerks and no unnecessarily large forces; high positioning accuracy at up to 4 m/s. Even open liquids can be transported
  • Dynamic buffer. The transported material can be accumulated and grouped during the movement.
  • Synchronisation, stopping and starting can be accomplished at any of the stations on the entire path
  • Maximum use of the machine volume. Outward and return path as well as the curves can actively transport material
  • The movers of the XTS system can always run with the flow of product. No return trip or return stroke is necessary. A change of format can be accomplished when changing product without stopping production, just by means of a software setting
  • Low mechanical wear since only the mover requires mechanical bearings. There is no need for: gears, belts, guide rollers and clamps
  • Reduced energy consumption due to lower friction and possible regenerative braking (the brake energy from one transported material can accelerate another)
  • High positioning accuracy reduces the expenditure. The compensation of inaccuracies as required in common transport solutions is not necessary: stretching of chains due to load and wear, re-tensioning of toothed belts, mechanical backlash during a load change

Customer products in operation

An example of an actuator in the electronic industry that has been assembled
and tested by XENON.

Product Image
  • Electroacoustic transducers

Key processes in assembly

Our wide expertise in technology is the perfect foundation
for your individual automation solution.

  • Handling

    Precise handling of delicate membranes to prevent damage

  • Bending and Cutting

    Automated processes to shape and cut thin wires

  • Pre- and Final Assembly

    Components are joined to ensure mechanical stability and optimal acoustic properties

  • Inspection and Testing

    Minimization of noise during assembly to avoid interference with acoustic testing

  • Packaging and Sealing

    Blister Belt, Palletizing, ...

Automation and Assembly Portfolio

XENON assembly and inspection solutions for electronic actuators
ensure precision and scalability for high-performance industrial and consumer applications.

Positionssensoren

  • Drosselklappenstellung
  • Fahr- beziehungsweise Bremspedalstellung
  • Weg- und Winkelpositionen in Dieseleinspritzpumpen
  • Füllstand im Kraftstoffbehälter
  • Lenkwinkel
  • Neigungswinkel
  • Ultraschall- und Radarsensoren

Drehzahl- und Geschwindigkeitssensoren

  • Kurbelwellendrehzahlen
  • Nockenwellendrehzahlen
  • Dieseleinspritzpumpendrehzahlen
  • Raddrehzahlen
  • Drehratensensoren
  • Getriebesensor
  • Wegstreckensensoren

Drucksensoren

  • Saug- beziehungsweise Ladedruck
  • Kraftstoffdruck
  • Bremsdruck  
  • Reifendruck
  • Hydraulikvorratsdruck (bei ABS und Servolenkung)
  • Kältemitteldruck
  • Modulationsdruck (Automatikgetriebe)

Temperatursensoren

  • Ansaug- beziehungsweise Ladelufttemperatur
  • Umgebungs- und Innenraumtemperatur
  • Verdampfertemperatur (Klimaanlage)
  • Kühlwassertemperatur
  • Motoröltemperatur
  • Kraftstofftemperatur
  • Reifenlufttemperatur

Kraft- und Drehmomentsensoren

  • Pedalkraft
  • Antriebskraft
  • Brems- und Lenkmomente
  • Gewicht der Fahrzeuginsassen (bei adaptiven Rückhaltesystemen)
Image

Magnetic

Magnetic actuators use electromagnetic forces to generate linear or rotary motion, often through solenoids or coils.

Image

Piezoelectric

Piezoelectric actuators deform materials under an electric field, enabling highly precise movements for applications like optical adjustments.

Image

Electrostatic

Electrostatic actuators use electric fields to move charged elements, offering fine control for microelectromechanical systems (MEMS).

Image

Linear Electric

Linear electric actuators convert electrical energy directly into linear motion, commonly used for precise, controlled movement in various systems.

Anwendungsfelder

Konsumelektronik

  • Audio-, Foto- & Videogeräte
  • Freizeitelektronik
  • Sportelektronik
  • Werkzeuge
  • Spielzeuge
  • ...

Datentechnik

  • Großrechnersysteme
  • PC-Systeme
  • Datennetzwerke
  • Abrechnungssysteme
  • Bürotechnik
  • Sicherungssysteme

Kfz-elektronik

  • Motorelektronik
  • Getriebeelektronik
  • Informationselektronik
  • Sicherheitselektronik
  • Verkehrsleitsysteme
  • ...

Industrieelektronik

  • Steuer- und Regelungstechnik
  • Industrieautomation
  • Prozessautomatisierung
    Leistungselektrik
  • Medizintechnik
  • Energieversorgung

Telekommunikation

  • Endgeräte
  • Vermittlungssysteme
  • Navigationsgeräte
  • Verkehrsinfrastruktur und
    Signaltechnik
  • Daten- und Signalübertragungsgeräte
ImageImage

Case Story – Automatisierte Steckverbinder-Montage (evtl. Lumbergstecker)

Zur präzisen und effizienten Montage von Steckverbindern konstruiert XENON vollautomatische Rundtaktanlagen sowie lineare Transfersysteme

Bis zu 20 unterschiedliche Prozessschritte vollzieht eine vollautomatische Anlage je Montagevorgang – Kurvensteuerung, elektrische Servoachsen und Industrieroboter stellen dabei Flexibilität, Genauigkeit und Qualität der Produktion sicher.

Die Anlage orientieren sich an Kundenanforderungen: Ob Prüfung , Montage von Einzelteilen und Gehäusen oder final montierten Steckverbindern.

Qualitätsmanagement

Bereits während der Montage stellen innovative Technologien und höchste Präzisionsstandards die Prüfung und Erfüllung qualitätsrelevanter Merkmale sicher

Dazu kommen folgende Systeme zum Einsatz:

  • Präzisions-Roboter mit hoher Wiederholgenauigkeit
  • Kameras mit industrieller Bildverarbeitung
  • Anschlussmaß-Messungen
  • Kraft-Weg-Messungen

Vollprüfungen können unmittelbar in der jeweiligen Maschine erfolgen.

Your way to smart production – with
automation solutions from XENON.

Your way to smart production – with
automation solutions from XENON.

Key Technologies for Electronic Connectors

Image

Feeding

Vibratory Feeder, Bowl Feeder, Centrifugal Feeder, Flex Feeder

Image

Injection Molding

Automation of
injection molding processes

Image

Joining

Assembling, Snapping, Soldering, Gluing, Riveting,
Screwing, Welding

Image

Cleaning

Plasma activation, CO2 cleaning,
Laser cleaning

Image

Dispensing

Dispensing  under vacuum, 1C/2C adhesive dispensing, Solder plast dispensing

Image

Calibrating

Calibration in operating temperature ranges from -40°C to 120°C

Image

Testing

Leakage test, Optical test,
Functional test

Image

Packaging

Tray, Tube, Tape-&-Reel
Packaging

30 Years of Automation Excellences

Customer Products

A selection of electronic actuators for which XENON has developed and built automation systems.

Reference Projects

Assembly and Testing Line for Electroacoustic Transducers


Example References (TAL, ICM, ...) Evtl. Slider 

To Do

  • Verlinkungen zu Referenzen Landingpage (TAL / ICM) (SGü, Ham)
  • Medical Veranstaltungen (Teaser Messen Medical) (SGü)
  • Videoclip TAL (SGü)
  • Bilder Kundenteile (SGü, Ham) 
  • Gesamtlayout und Texte überarbeiten
  • Medcell Informationen? (Pflichtenheft / Eigenschaften)
  • Sicherheit der Produkte und Fertigung
  • Auflistung Qualitätsstandards, QM & Sicherheit (GMP, ...)  
  • Fotos AP (SGü)
  • Innovationsthemen? (V2 - Augmented Reality)
  • Quotes von Kunden? (V2 - Ham) 

Customer product

Electroacoustic transducers for headphones

Automation requirements

  • Fully automated assembly of various transducer sizes
  • Scalable production with high throughput
  • Seamless integration of third-party technologies
  • High precision and repeatability in assembly processes
  • Automatic Optical Inspection (AOI) for quality assurance
  • Acoustic End-of-Line (EOL) testing for performance validation
  • Efficient and reliable packaging solutions

Testing and Packaging of an SMD Contact Spring


Example References (TAL, ICM, ...) Evtl. Slider 

To Do

  • Verlinkungen zu Referenzen Landingpage (TAL / ICM) (SGü, Ham)
  • Medical Veranstaltungen (Teaser Messen Medical) (SGü)
  • Videoclip TAL (SGü)
  • Bilder Kundenteile (SGü, Ham) 
  • Gesamtlayout und Texte überarbeiten
  • Medcell Informationen? (Pflichtenheft / Eigenschaften)
  • Sicherheit der Produkte und Fertigung
  • Auflistung Qualitätsstandards, QM & Sicherheit (GMP, ...)  
  • Fotos AP (SGü)
  • Innovationsthemen? (V2 - Augmented Reality)
  • Quotes von Kunden? (V2 - Ham) 

Customer product

SMD contact spring

Automation requirements

  • Safe handling (gripping and transporting)
  • Bulk material separation
  • Qualified testing of individual contact springs
  • Sorting of IO/NIO parts
  • Fully automated packaging (blister incl. belt cutting)
  • ESD compliance

Worldwide leading companies rely on XENON automation systems

Would you like to know more about
our solutions for electronic actuators?
Just give us a call.

Flyer
Contact us

Your Contact

Daniel Schümann
Head of Sales & Project Application

Image