Content. Consulting and Service 22

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1 EN Solutions

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3 Content Process Automation 2 TransferLine 4 Fields of Application 6 High-speed Data Cables 6 Cables with FAKRA Connectors 7 Airbags 8 Other Applications 9 Test Automation 10 EasyTest FlexiTest EcoTest RotaryTest MultiTest SpecialTest TAC Test Application Components 18 Test Devices and Software 19 Fields of Application 20 Test Processes 21 Consulting and Service 22 1

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5 Process Automation Schleuniger is the leading supplier of customized solutions for challenging applications in the wire processing industry. Those solutions are based on the Schleuniger transfer system, TransferLine. Of course, we also offer professional project management and guarantee the careful handling of confidential data. Fast and reliable customer service completes our profile.

6 TransferLine Accurate and flexible linear system The modular and standardized design of the basic system ensures cost-effective solutions and enables precise tailoring to the application. The tool carrier concept is designed specifically for axial processing of individual cores and multiple conductor lines. The tool carrier (shuttle) can be indexed laterally, vertically and axially. Part feeding and assembly stations, as well as test and marking stations, can be integrated according to individual requirements. In addition, the system can be extended with peripheral devices. 4

7 Process Automation Processing possibilites of the TransferLine Processing of loose or strapped contacts, single or multiple part housings, single or multiple core lines, screened lines, crimping, welding, injection molding, integration of special processes, quality checks, material feed, placing down, and winding - This is only a selection of the competencies we offer you, in particular for airbag, FAKRA and HSD applications. In addition, we offer fully automatic and semiautomatic solutions for numerous other applications. 5

8 Fields of Application High-speed data cables (HSD) HSD cables are used for a range of applications both inside and on the exterior of vehicles, such as for the transmission of image data, for multi-function displays and infotainment systems for rear-seat passengers. They are used when cables must function reliably even under extreme conditions. Schleuniger offers fully automatic equipment for processing the shielded, four-core HSD cable from the drum right through to the assembly of housings. 6

9 Fields of Application Cables with FAKRA connectors Schleuniger offers various machine platforms for manufacturing cables with FAKRA connectors. The portfolio includes semi-automatic and fully automatic systems. A variety of standard modules for shield processing, rotary stripping, two-sided crimping and electrical high-voltage testing form the basis for processing these coaxial cables. Economical partial automation is also possible with our tried and tested special CrimpCenters. Process Automation 7

10 Fields of Application Airbags When delivered, Squib connectors consist of several components and must be terminated and assembled. This requires flexibility to handle different cable types, such as twisted pair cables, sheathed cables, and single wires, as well as flexibility with regard to coding and variable cable lengths. 8

11 Fields of Application Other applications In addition to our specialist fields of HSD, airbag and FAKRA applications, we also have extensive experience in the automation of numerous other applications, such as ABS, exhaust management, high-temperature and other sensor applications. Our proven TransferLine and our special CrimpCenters form the basis for this and can be supplemented with stations for special processes. Process Automation 9

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13 Testautomation In the field of testing/test automation, Schleuniger offers customers everything they need from a single source. Like no other supplier combines Schleuniger testing intelligence (test devices and their software) and highest competence in mechanical engineering. In mechanical engineering we use standardized modules in order to offer solutions that are both first-class and cost-effective. If required, we are also able to create custom-made solutions for your highly specific test needs. Our solutions enable you to test cables and cable harnesses, as well as plug connectors and electromechanical assemblies with regard to a variety of criteria.

14 EasyTest 1000 Simple, compact and cost-effective The table systems that are assembled using standard components from the EasyTest 1000 series are characterized by simple handling and minimum space requirements. The parts feed for these systems is exclusively manual. For this reason, the EasyTest 1000 systems are our most cost-effective implementations. They are primarily used for electrical testing of small cable harnesses. 12

15 FlexiTest 2000 The flexible, basic platform Systems from the FlexiTest 2000 series are the basic platform for our automation systems. They can be equipped with up to five infeed axes and enable the user to respond flexibly to version changes. The exchange of part-specific modifications with the corresponding program change is extremely simple. Hence, the operator can implement the change to a new product within the shortest possible time. Systems from the FlexiTest 2000 series are ideal for testing sample parts and pilot series because the applied modifications can continue to be used when the product goes into series production and automated testing is implemented. This means that during the introductory phase of a new product, the parts are tested with the same equipment as during the subsequent series production. With this test-on-demand approach, we support our customers with production start-ups and with the spare parts business. We would be happy to carry out the testing of your initial component for you, naturally with the corresponding test certificate. Test Automation 13

16 EcoTest 3000 Reliable handling of large volumes and complexity Systems from the EcoTest 3000 series are semi-automatic solutions. They represent the ideal bridge between higher volumes and high complexity. EcoTest 3000 systems enable the operator to handle complex components and hybrid assemblies, while the system takes care of testing and process tasks. The systems use two workpiece carriers, which significantly reduce the complexity compared with highly automated systems, but still maintain attractive cycle times. EcoTest 3000 systems have a modular design and can easily be modified for new variants. They are designed for medium volumes. 14

17 RotaryTest 4000 Rotative test solution for high volumes It s all in the name the basis for our systems from the RotaryTest 4000 series is a round table that is equipped with workpiece carriers. Our basic versions come with either six, ten, or fourteen workpiece carriers. RotaryTest 4000 systems are usually equipped with an electrical testing system, camera testing, labelling, and an unloading handling system. Additional processes can also be integrated. RotaryTest 4000 systems are designed for high volumes with a minimum cycle time of four to five seconds. They can be set up with both semi-automatic and fully automatic feed-in systems. Test Automation 15

18 MultiTest 5000 Highly flexible testing of short to medium length cables The MultiTest 5000 provides the highest level of testing flexibility. Systems from the MultiTest 5000 series are based on a workpiece carrier circulation system. A standardized setup enables a maximum of six processes to be carried out. Additional process steps can be added, however, this means that the system can no longer be set up as a standardized platform. MultiTest 5000 systems are mainly used to process short to medium length cables, with connectors on at least one end. As a general rule, components are fed into the systems manually. However, the unloading can be carried out fully automatically. MultiTest 5000 systems function with a minimum cycle time of five to six seconds. 16

19 SpecialTest 9000 Tailored entirely to your requirements SpecialTest 9000 solutions are systems that are not based on our platform technology. This means that starting with the white-sheet design, through to the processes and the software, the concepts are tailored entirely to the customer s requirements. The resulting solutions can involve robot cells, unorthodox testing applications, or extensively interlinked individual machines. There are no limits to SpecialTest 9000 systems, as long as they can be combined with our testing applications. Our staff works together with you to develop the best possible solution, prepare the specification sheet, and implement your system. Test Automation 17

20 TAC Test Application Components The basis of test automation Test Application Components (TAC) includes all components required to implement the testing tasks in a system. The heart of these testing systems is formed by our high-quality test devices, of which we offer a wide portfolio together with the corresponding adapters. In addition to test devices, Schleuniger offers complete modules in the TAC category, which can be integrated into a test system. With these components, our customers establish the interface to our know-how. Naturally, we apply all our expertise to support our customers during the implementation of the integration. 18

21 Test Systems and Software The heart of our test systems The portfolio of our standard test devices ranges from simple low-voltage tests, such as testing for continuity and short circuits, right through to high-voltage tests up to 2 KV DC (AC optional). Our automatable AST/AST-H test system combines our entire testing expertise in a single device. Standardized interfaces are as much a natural part of our test devices as are the graphical display of results and meaningful statistics. Test Automation 19

22 Fields of Application Cables and cable harnesses Plug connectors and plastic parts Hybrid assemblies Function modules 20

23 Test Processes Electrical connection tests Presence checks Continuity test Short circuit Open Reverse polarity Resistance High voltage Connectors Clips Cable ties Cable shoes Locking pins and latches Alignment and fastening pins Caps and covers Other presence checks Mechanical checks Pin height/pin length Pin material (plastic/metal) Swash circumference check Forces Torques Temperatures Vacuum pressure tests Component checks Electrical Values Capacitors Diodes Coils Resistors Currents LEDs Static and dynamic HALL sensor testing Visual checks Swash circumference check 3D scanning Hole diameter Pattern matching Colors Text Data matrix Barcode Test Automation 21

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25 Die Erstellung von effektiven und perfekten Prüfapplikation basiert auf erprobten Standards und einem modularen und solidem Baukastensystem. Diesem Anspruch folgend haben wir in den letzten 15 Jahren unser Prüfzellenkonzept immer mehr verfeinert. Die in dieser Zeit entstandenen Applikationen reichen von einfachen elektrischen Kontaktierungen über visuelle Prüfungen bis hin zu hochgenauen Baugruppentests. Immer mehr Applikationen benötigen nicht nur den Test und die Verifizierung, sondern die Programmierung und Optimierung innerhalb der eigentlichen Prüfung. Diese Anforderungen bestmöglich zu erfüllen, war schon immer unser Ziel. Aus diesem Grund haben wir vor über 10 Jahren damit begonnen unsere Prüfsysteme hierfür zu optimieren. Der TouchOne und der AST (application Consulting spezific tester) sind das and Ergebnis dieser Service Entwicklung. Beide Systeme vereinigen optimal Testfunktionalität, Visualisierung und Steuerung der Prüfaufgabe. Damit hat der Anwender immer nur eine Bedienoberfläche. Your project begins long before you place your order with Schleuniger and does not end with the Er delivery muss of sich your nicht modules mit unterschiedlichen and systems. Our Systemen specialists vertraut have a machen, broad understanding sondern befindet and sich deep immer expertise im in gleichen both process System. automation Unsere Prüfzellen and test automation bieten jedoch and noch can einen provide weiteren, advice throughout erheblichen your Vorteil product gegenüber allen development anderen process. Systemen. And, Die of Inbetriebnahme course, our service und team der Service is available lassen after sich delivery wesentlich via einfacher our technical durchführen. center and Fertige through Softwaremodule our service . und nur eine globale Steuerung vereinfachen die Umsetzung Ihrer call Prüfaufgabe.

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