Automated Through the Welding Process

In the automotive supply industry, short cycle times, high availability, and consistent quality are crucial. At the same time, demands for automation and cost-effectiveness are increasing. A stud welding system implemented by AKE-Systemtechnik GmbH for the automotive supplier Meleghy at its Gera facility demonstrates how these factors can be combined. For the reliable handling of welded nuts, the system utilizes, among other things, electric small-part grippers from the GEP2000 series by Zimmer Group. The solution is supplemented by tool changers and shock absorbers, resulting in a coordinated component package designed for demanding day-to-day production.

Harsh Environment, Short Cycle Times

In resistance projection welding, weld nuts are automatically fed and welded to the designated components. For the automation components used, this means high dynamics and short cycle times in an environment subjected to high stresses due to the welding process. In addition, the system operates in three shifts. High system availability is therefore crucial—especially in the automotive supply industry, where just-in-time processes must function reliably.

For this application, AKE-Systemtechnik relies on components from the Zimmer Group. At the heart of the system is the GEP2006IL-03-B small-part electric gripper from the GEP2000 series. Its task is to securely grip and handle the welding nuts in the automated process. The gripper must not only operate quickly and precisely but also withstand the demanding environmental conditions over the long term.

Secure Gripping, Reliable Feeding

A particular challenge of the system lies in the wide variety of products and the supply of individual components. For the automated welding process, the weld nuts must be reliably transferred from the feeding system. At the same time, the gripping process must be intelligently monitored. Was a weld nut picked up correctly? Is it in good condition or not? Or was it possibly lost during the process?

Especially in an automated process, this monitoring is a crucial component of quality assurance. After all, any undetected error can have an immediate impact on the rest of the production flow. Thanks to IO-Link technology, the GEP2000 plays a central role in automated handling and helps ensure that processes are safe and reproducible.

The GEP2000 series of electric small-part grippers is designed for automated handling tasks. They combine a compact design with precise, controlled gripping motion. This makes them particularly suitable for applications where small components must be moved quickly and reliably. In the projection welding system from AKE-Systemtechnik, this advantage comes into play under demanding cycle time and environmental conditions.

Components for the Entire Process

In addition to the GEP2000, other Zimmer Group components are part of the system. A tool changer enables the automated switching of the end effectors in use. Furthermore, shock absorbers support mechanical safety and the controlled deceleration of moving components.

The interaction between the individual components is crucial here. This is because at AKE-Systemtechnik, the focus is not on individual components, but on a reliable overall solution. The high quality and low failure rate of Zimmer Group products form an important foundation for the required system availability.

Technical Support as Part of the Solution

However, for AKE-Systemtechnik, the collaboration with Zimmer Group is not limited to the supply of components. Especially in demanding automation projects, technical support during development, installation, and commissioning plays a crucial role. Thanks to close support, questions can be clarified directly during the ongoing process, and solutions can be developed collaboratively.

Martin Meier, responsible for design, development, and project management at AKE-Systemtechnik, particularly highlights the collaboration with the Zimmer Group’s field sales team and technology specialists: “Particularly noteworthy is the highly competent and friendly communication and the mutual respect—from the assembly line all the way up to senior management.”

Even when technical opinions differ, the collaboration remains constructive. “The fair and goal-oriented approach to resolving disagreements is unique and sets us apart from competitors,” says Meier.

Reliability for Automated Production

Meleghy’s projection welding system demonstrates what matters most in automation solutions for the automotive supply industry: The components must function quickly, precisely, and reliably—even under heavy loads during three-shift operation. The GEP2000 plays a central role in the automated feeding and handling of the welding nuts.

For AKE-Systemtechnik, quality, availability, and on-time delivery are key factors in choosing Zimmer components. Combined with on-site technical support, this creates a solution that not only replaces individual manual workstations but is also designed for a stable and cost-effective overall process. In this way, automation helps reduce errors, increase productivity, and optimize the system’s profitability.

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