Assembly Solutions
for Smart SensINg

Assembly lines and test systems for sensors

The rapid development of technologies, materials and industry (IIoT) is constantly driving the need for more precise, more adaptable and more powerful sensor solutions. In particular, ever smaller sizes are constantly presenting developers and manufacturers with new challenges.

With over 30 years of experience in production automation for sensors, we know the special requirements of the industry and know what is important. This long-standing expertise and the process know-how we have acquired form the basis for our customized and cost-efficient automation solutions.

Our key competencies for electrical sensors are

  • Dealing with highly diversified product ranges
  • Extensive technology portfolio for different environmental conditions
  • Integration of external systems
  • Extensive AOI systems for quality assembly
  • High-precision calibration and test processes
  • Intelligent process data management
  • Automatic set-up processes for a wide range of sensor variants

High-Speed-Linear-Transportsystem

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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

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Curved Segment

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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

Application fields

MobilitY

Smart Home

Entertainment

Industry

Key assembly processes

Our wide expertise in technology is the perfect foundation for your individual sensor automation solution.
Discover our entire technology portfolio.

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  • Interface

    • Connector / Cable assembly
    • Soldering
    • AOI Soldering

  • Identification

    • Labeling
    • Lasering
    • Marking

  • Testing

    • Function test
    • Testing under various environmental conditions such as temperature and pressure
    • EOL test

  • Housing assembly

    • Crimping
    • Welding
    • Leak test

  • Feeding and Separation

    Bulk or Strip Material (Pins, Body/Housing, Insulation)

  • Joining and Positioning

    Pick and Place, Cam-Controlled Assembly, Robot Handling

  • Pre- and Final Assembly

    Press-Fit, Crimping, ...

  • Testing and Selection IO/NIO

    Quality Assurance (Function, Pin Position, Tightness, ...)

  • Identification and Traceability

    Labeling, Lasering, Marking

  • Packaging and Sealing

    Blister Belt, Palletizing, ...

Automation and Assembly Portfolio

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Position sensors

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Acceleration sensors

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Electric sensors

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Temperature sensors

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Ultrasonic sensors

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Optical sensors

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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
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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 Sensors

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Feeding

Vibratory Feeder, Bowl Feeder, Centrifugal Feeder, Flex Feeder

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Handling

SCARA Robots, 6-Axis Robots, Multi-Axis Gantry Systems, High-Speed Pick and Place

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Joining

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

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Pressing/Press-Fit

 "Force-Displacement" monitored Press-Fitting of Multipin Plug Contacts into Printed Circuit Boards (PCB)

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Injection Molding

Supply and Processing
of Inserts, Contact Assembly

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Crimping

Crimp to Crimp, Crimp to Seal, UniCrimp, Sealing

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Testing

Optical Inspection (AOI), Quality Control, Leakage Tests, Flow Tests, Electrical Tests, EOL Function Tests

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Packaging

Tray, Tube, Tape & Reel Packaging, Blister Tape, Bag Packaging

30 Years of Automation Excellences

Customer Products

XENON has developed and constructed automations for a variety of electronic sensors.

REFERENCE PROJECTS

Assembly and inspection Line for position and speed sensors


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

Speed sensor, Position sensor

Automation requirements

  • Fully automatic assembly line consisting of 3 standard modules
  • Flexible technologies for manufacturing different sensors
    at one production line
  • Setup time up to a maximum of 15 minutes
  • Digital monitoring of all process parameters
  • Order management and connectivity to customer's MES system  

    Fully automated assembly and packaging of pressure sensors


    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

    Pressure sensor

    Automation requirements

    • Fully automated assembly and packaging (from individual part to ready-to-sell)
    • Highly automated production line for setup-free production of over 15,000 sensor variants
    • Inline adjustment and calibration of the pressure sensors
    • Order management incl. single-piece flow strategy with connection to the customer database

    Assembly, calibration and test line for pressure sensors


    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

    Pressure sensor

    Automation requirements

        • Complete assembly of the 7 individual parts

        • Pressure pre-forming

        • Hot caulking housing

        • Cycle time 6 seconds

        • Digital monitoring of all process parameters for order management and connection to the customer's MES system

        • Small footprint

        Worldwide leading sensor companies rely on XENON automation systems

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

        Contact us

        Your Contact

        Matthias Funk
        Sales Manager

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