Quality, flexibility and speed

Highest quality requirements, great variety of types and short deliveries: These are the main parameters for which Schmersal production is organised. For this reason, the level of vertical integration is consciously high: The processes can thus be held better under control and especially a reproducible level of quality assured. Both the moulding of plastic parts and the mechanical processing of cast parts, the assembly of electronic circuit boards, the making of the tools and the assembly of the end products is all carried out on our premises.

Injection moulding    machine

Plastic moulding department

In our Wuppertal plant, 30 injection moulding machines of up to 100 t are in operation. Some of the machines are fitted with automatic material-handling equipment.

Tool room

Our tool room produces high-precision moulding tools and is equipped with the necessary equipment and know-how in order to be able to carry out all applicable maintenance and repair work. In addition to conventional and CNC machines, we have several wire eroding machines, spark-eroding machines and also two eroding centres with automatic tool-changing facilities.

Automatic silk-    screen printing and    SMD insertion machine

Electronic production

Five SMD automatic insertion machines produce the circuit boards for sensors, safety monitoring modules and customer-specific control systems. The solder paste is spread on fully automatically using the silk-screen printing process.

Quality control in electronic production

All electronic cards go through a sight inspection, an electrical test and a function test under pre-determined temperature cycles. Sensors are balanced after assembly for pre-determined switching distances by means of a laser-trimmer system.

Assembly station in    electronic production

Sight inspection station    for assembled circuit    boards

Laser-trimmer for    sensor balancing

Fitting

Since we manufacture almost all our products in a great variety of types, most of the devices are completely assembled by a single person at an individual station. All final assembly stations are provided with test devices which call up the particular test program for the order from a central computer by means of a barcode and store the test results in a central database. Deviations from the required values can thus be determined quickly and corrective measures taken, if necessary. The test devices are developed and built by specially-trained engineers in our own development department.
For ranges of devices which we produce in larger quantities, we also use automated assembly steps. Thus, we have built a completely linked assembly line for the new USP Lift-Positioning System. On this line, all data for a unit are carried to all work places; using the serial number, the test data for the particular unit can be retrieved, even years later.

Individual work place    for assembly of the AZ 17    range

Automatic fitting of    screws on AZ 15/16    ranges

USP assembly line