Assembly & Testing

Dürr Factory Assembly Systems - competence in the field of final assembly

Dürr is a leading supplier of production systems and services for the automotive industry. Approximately 6000 staff are operating worldwide, which ensures a presence near to the customer and the highest standards in quality. Apart from painting, final assembly technology has formed part of Dürr's core competencies for a long time. Today Dürr supplies technologies for almost all processes along the production chain in the automotive industry, from body to paint shop and final assembly.

Dürr Factory Assembly Systems (FAS)

The Dürr business unit Factory Assembly Systems (FAS) offers a complete range of intelligent solutions for final assembly, beginning with project planning and the supply of machines and systems up to turnkey plants.
With about 50 staff members, Dürr Consulting is an experienced service provider for the engineering of production and assembly processes through to complete factories, including logistics and optimisation of the supplier chain. Furthermore FAS supplies proven and innovative conveyor systems for automotive plants and other industry branches as well as the entire equipment for assembly, filling and testing tasks covering the main fields in pre-assembly, final assembly and end-of-line. The combination of product and process know-how enables FAS to successfully work in the field of general contracting. FAScontract, the turnkey concept by Dürr FAS, focuses on project planning/ design and project management of largescale turnkey projects.

Co-operative competence

Together with subsidiaries of worldwide renown, Dürr Systems GmbH completes its offer in the field of final assembly: Dürr Assembly Products GmbH (former Schenck Final Assembly Products GmbH), Dürr Somac GmbH and CPM S.p.A. offer a broad range of innovative products. Here, in tight cooperation with customers' planning, design, maintenance and production departments, experts design integrated concepts for high flexibility. Process safe sequences, low failure rates and short maintenance and repair times ensure high availability and minimum piece costs.

Innovative conveyor systems

The market success of Dürr conveyor systems is based on continual innovation and compliance with customer-specific requirements. With the product groups FASfloor and FAStrolley Dürr Systems GmbH is offering an extensive range of floor and overhead conveyors for body and paint shop as well as for final assembly. In combination with FASmotion, the contact-free power and data transfer system developed by Dürr, maximum flexibility and availability in conveying can be achieved. The modular Twin Trolley System® (TTS) accommodates the drives on the rail and not on the trolley. Thus, an on-board control is not required and gradients can be overcome without any additional installations. Another innovation is the automated guided vehicle FASmatic® which is powered and controlled via FASmotion. This most efficient floor conveyor stands for the efficient implementation of body marriage but is also equipped for any conceivable challenge in logistics.

Increased flexibility

To improve flexibility and reduce investment, Dürr developed the modular final assembly FAStplant®. The installation of pre-mounted and tested modules allows a short plant start-up time and the modular design allows factories to be extended, scaled down or completely relocated according to requirements. The adaptation of new models and the integration of new process steps require less time and less expense.

Assembly processes

FASsembly comprises Dürr FAS' entire product range for final assembly. Front and rear axle component assembly is an area Dürr Assembly Products GmbH has considerable expertise in. This includes the assembly as well as the pre-setting of the axle geometry. Body chassis marriage is a very demanding and complex assembly process, for which Dürr supplies equipment for manual and automatic fitting.
Dürr Somac GmbH has developed technical systems for fully automatic window and glass roof assembly. Here industrial robots and 3D camera systems are applied. In developing this, Dürr Somac was able to benefit from competence gained in the fields of handling systems, robot application, image processing systems, heated medium metering systems and hydraulic components. For the installation of pre-assembled modules such as front-end or cockpit Dürr Somac supplies handling and fitting facilities with the emphasis on automated process and complex fitting tools.

Filling and testing tasks

FASprofill leak test and filling systems from Dürr Somac are applied for exact filling of vehicle systems with operating fluids such as: power steering, radiators, ABS, brake, clutch, motor, gearbox, air-conditioning. Dürr Somac has a wide scope of systems from mobile individual systems up to combined filling systems. For customers in the supply branch Dürr Somac is producing equipment for the completion of pre-mounted vehicle modules such as brake or clutch line systems, gearboxes or shock absorbers. With the product group FAStest Dürr FAS supplies all needs in the field of testing on a high quality level as Dürr Assembly Products GmbH is renowned for its test systems. Contact-free lasers are applied in the wheel alignment stand x-wheel to meet highest requirements with regard to reproducibility.
With the headlamp setting system xlight headlamps can be set, as too can the distance sensors. X-light can also be applied to check luminous intensity and control devices can be programmed. On the multi function rolling road xroad all relevant functions of the vehicle are tested under realistic conditions in a dynamic test operation.
FAS offers suitable systems for fast, efficient and precise test and adjustment of driver assistance systems which can be integrated into headlamp aiming or wheel alignment stands or be installed separately. All electrical and electronic testing tasks in assembly and end of line are covered by the FAStronic product line. The scope of solutions contains "classical" ECOS, ECU diagnosis as well as module and infotainment testing. An intelligent and flexible distribution of testing tasks is possible with the central production management system x-line prosys. X-line is synonymous with the intelligent automotive production. The software system forms the platform for the uniform control system and operator guidance in the total field of vehicle final assembly.

Bundled expertise

Almost all automotive manufacturers fall within the range of customers of Dürr FAS. The Business Unit is successful in all important markets - which secures local presence on a worldwide basis. With own development departments, professional project management and a worldwide service network, Dürr FAS is an efficient partner of automotive manufacturers and suppliers with regard to conveying, assembly, filling and testing tasks.

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