HAHN Automation Group enables scalable Actuator Production
For the production of complex electronic valve actuators, the HAHN Automation Group developed a multi-site solution combining injection molding, precise assembly, and high-efficiency end-of-line testing.
With a 50% cycle time reduction and seamless coordination between locations, the project sets a new benchmark for flexible, scalable automation.
#Automotive #Electronics #Actuator #AssemblyLine
- Advanced Joining & Testing Technologies
- Assembly across two HAHN Sites
- Full-automatic Assembly Line
Challenge
The customer required a solution for assembling electronic valve actuators with a wide range of integrated processes: injection molding of stator components, pre-assembly of housings, greasing, screwing, plastic laser welding, and end-of-line (EOL) testing.
A key challenge was the division of responsibilities across two production sites, each with unique process capabilities. Additionally, EOL testing needed to be optimized to achieve a 50% reduction in cycle time—without compromising on quality or throughput.
Developing a Solution
To manage this complexity, HAHN Automation Group implemented a coordinated twosite concept. Injection molding and stator processes were carried out at the Diepenau site, while final assembly and EOL testing took place at the headquarters in Rheinböllen. The system architecture allows for scalable production (up to 128-up IMM setups) without duplicating downstream stations.
Core technologies such as in-mold technology, PCB joining, precision greasing, and laser welding were tightly integrated, supported by AGV systems and buffer/cooling for 4,300 parts.
